CYLINDER BLOCK INSPECTION

Inspect for flatness.

1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head cap for warpage.

   Maximum warpage
   0.10 mm (0.0039 in.)

   If warpage is greater than maximum, replace the cylinder block.

Visually check the cylinder for vertical scratches.

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

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

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 92.000 - 92.010 mm (3.6220 - 3.6224 in.) Mark 2 92.010 - 92.020 mm (3.6224 - 3.6228 in.) Mark 3 92.020 - 92.030 mm (3.6228 - 3.6232 in.)

   Maximum diameter
   STD 92.23 mm (3.6311 in.) O/S 0.50 92.73 mm (3.6508 in.)

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

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*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.

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*a	Size Mark
*b	Front Mark (Arrow)
*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.

   Standard diameter
   STD Mark 1 91.92 - 91.93 mm (3.6189 - 3.6193 in.) Mark 2 91.93 - 91.94 mm (3.6193 - 3.6197 in.) Mark 3 91.94 - 91.95 mm (3.6197 - 3.6201 in.) O/S 0.50 92.42 - 92.45 mm (3.6386 - 3.6398 in.)

2. Measure the cylinder bore diameter in the thrust directions (See step 4).

3. 

   Text in Illustration

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

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

   Standard oil clearance
   0.070 - 0.090 mm (0.0028 - 0.0035 in.)

   Maximum oil clearance
   0.16 mm (0.0063 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.

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.

Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

If the clearance is greater than maximum, replace the piston.

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, 120 mm (4.72 in.) from the top of the cylinder block.

3. 

   Using a feeler gauge, measure the end gap.

   Standard end gap
   No. 1 0.270 - 0.510 mm (0.0106 - 0.0201 in.) No. 2 0.470 - 0.740 mm (0.0185 - 0.0291 in.) Oil 0.200 - 0.520 mm (0.0079 - 0.0205 in.)

   Maximum end gap
   No. 1 1.21 mm (0.0476 in.) No. 2 1.44 mm (0.0567 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
   0.03 mm (0.0012 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
   34.012 - 34.024 mm (1.3391 - 1.3395 in.)

2. Subtract the piston pin diameter measurement (See step 5) from the bush inside diameter measurement.

   Standard oil clearance
   0.012 - 0.020 mm (0.0005 - 0.0008 in.)

   Maximum oil clearance
   0.03 mm (0.0012 in.)

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

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

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*a	Center Journal

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 69.982 - 70.000 mm (2.7552 - 2.7559 in.) U/S 0.25 69.982 - 70.000 mm (2.7552 - 2.7559 in.) U/S 0.50 69.495 - 69.505 mm (2.7360 - 2.7364 in.)

   Crank pin diameter
   STD 58.982 - 59.000 mm (2.3221 - 2.3228 in.) U/S 0.25 58.745 - 58.755 mm (2.3128 - 2.3132 in.) U/S 0.50 58.495 - 58.505 mm (2.3029 - 2.3033 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.