CYLINDER BLOCK INSPECTION

Visually check the cylinder for vertical scratches.

If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

Text in Illustration

*a	No. 1
*b	No. 2
*c	No. 3
*d	No. 4
*e	Mark 1, 2 or 3
*f	Front

Inspect the cylinder bore diameter.

1. 

   Text in Illustration

   *a	Front
   *b	Thrust Direction
   *c	Axial Direction

   Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

   Standard diameter
   Mark 1 99.500 - 99.510 mm (3.9173 - 3.9177 in.) Mark 2 99.510 - 99.520 mm (3.9177 - 3.9181 in.) Mark 3 99.520 - 99.530 mm (3.9181 - 3.9185 in.)

   Maximum diameter
   STD 99.73 mm (3.9264 in.) O/S 0.50 100.23 mm (3.9461 in.)

   If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

Text in Illustration

*1	Ridge Reamer

Remove the cylinder ridge.

If the wear is less than 0.2mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

Text in Illustration

*a	Front Mark (Arrow)
*b	Size Mark
*c	Distance

Inspect the piston oil clearance.

1. Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston head.

   Distance
   61.27 - 61.33 mm (2.4122 - 2.4146 in.)

   Piston diameter
   STD Mark 1 99.450 - 99.460 mm (3.9153 - 3.9157 in.) Mark 2 99.460 - 99.470 mm (3.9157 - 3.9161 in.) Mark 3 99.470 - 99.480 mm (3.9161 - 3.9165 in.) O/S 0.50 99.950 - 99.980 mm (3.9350 - 3.9362 in.)

2. Measure the cylinder bore diameter in the thrust directions (See step 3).

3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

   Standard oil clearance
   0.040 - 0.060 mm (0.0016 - 0.0024 in.)

   Maximum oil clearance
   0.13 mm (0.0051 in.)

   If the oil clearance is greater than maximum, replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block.

   Tech Tips

   Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.

   

   Text in Illustration

   *a	No. 1	*b	No. 2
   *c	No. 3	*d	No. 4
   *e	Mark 1, 2 or 3	*f	Front
   *g	Front Mark (Arrow)

Inspect the piston pin fit.

1. 

   At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb

   If the pin can be installed at a lower temperature, replace the piston and pin as set.

Using a micrometer, measure the piston pin diameter.

Inspect the piston ring end gap.

1. 

   Insert the piston ring into the cylinder bore.

2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 140 mm (5.51 in.) from the top of the cylinder block.

3. 

   Using a feeler gauge, measure the end gap.

   Standard end gap
   No. 1 0.350 - 0.590 mm (0.0138 - 0.0232 in.) No. 2 0.470 - 0.720 mm (0.0185 - 0.0283 in.) Oil 0.200 - 0.520 mm (0.0079 - 0.0205 in.)

   Maximum end gap
   No. 1 1.29 mm (0.0508 in.) No. 2 1.29 mm (0.0508 in.) Oil 1.22 mm (0.0480 in.)

   If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

Using a rod aligner and feeler gauge, check the connecting rod alignment.

1. Check for bend.

   Maximum bend
   0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

   If bend is greater than maximum, replace the connecting rod sub-assembly.

2. 

   Check for twist

   Maximum twist
   0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

   If twist is greater than maximum, replace the connecting rod sub-assembly.

Inspect the piston pin oil clearance.

1. Using a caliper gauge, measure the inside diameter of the connecting rod bush.

   Bush inside diameter
   29.008 - 29.020 mm (1.1420 - 1.1425 in.)

2. Subtract the piston pin diameter measurement (See step 4) from the bush inside diameter measurement.

   Standard oil clearance
   0.004 - 0.012 mm (0.0002 - 0.0005 in.)

   Maximum oil clearance
   0.05 mm (0.0020 in.)

   If the oil clearance is greater than maximum, replace the bush.

   If necessary, replace the piston and piston pin as a set.

Inspect for circle runout.

1. Place the crankshaft on V-blocks.

2. Using a dial indicator, measure the circle runout at the center journal.

   Maximum circle runout
   0.06 mm (0.0024 in.)

   If the circle runout is greater than maximum, replace the crankshaft.

Inspect the main journals and crank pins.

1. Using a micrometer, measure the diameter of each main journal and crank pin.

   Main journal diameter
   STD 61.985 - 62.000 mm (2.4403 - 2.4409 in.) U/S 0.25 61.745 - 61.755 mm (2.4309 - 2.4313 in.) U/S 0.50 61.495 - 61.505 mm (2.4211 - 2.4215 in.)

   Crank pin diameter
   STD 54.988 - 55.000 mm (2.1649 - 2.1654 in.) U/S 0.25 54.745 - 54.755 mm (2.1553 - 2.1557 in.) U/S 0.50 54.495 - 54.505 mm (2.1455 - 2.1459 in.)

   If the diameter is not as specified, check the oil clearance (See steps Click here and Click here). If necessary, grind or replace the crankshaft.

2. Check each main journal and crank pin for taper and out-of-round as shown.

   Maximum taper and out-of-round
   0.02 mm (0.0008 in.)

   If the taper and out-of-round is greater than maximum, replace the crankshaft.