CYLINDER BLOCK INSPECTION

Push the check valve with a pin to check if it is stuck.

If stuck, replace the oil nozzle.

While covering A, apply air into B. Then check the oil nozzle for damage or clogging.

If there is an air leak, clean or replace the oil nozzle.

Push the check valve while covering A, and apply air into B. Check that air passes through the oil nozzle.

If air cannot pass through, clean or replace the oil nozzle.

Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

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

Visually check the cylinder for vertical scratches.

If necessary, replace the cylinder block.

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

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

Using a micrometer, measure the piston diameter at a position that is 10.7 mm (0.421 in.) downward from the center of the piston pin hole (refer to the illustration).

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

If the clearance is not as specified, replace the piston.

Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.362 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block.

Check each mark on the piston, piston pin and connecting rod.

Using a caliper gauge, measure the inside diameter of the piston pin hole.

Using a micrometer, measure the piston pin diameter.

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

Using a vernier caliper, measure the tension portion diameter of the bolt.

If the diameter is less than the minimum, replace the bolt.

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 the maximum, replace the crankshaft.

Inspect the main journals.

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

   Standard journal diameter
   66.988 to 67.000 mm (2.6373 to 2.6378 in.)

   If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

2. Check each main journal for taper and out-of-round as shown in the illustration.

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

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

Inspect the crank pin.

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

   Standard crank pin diameter
   52.982 to 53.000 mm (2.0859 to 2.0866 in.)

   If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

2. Check each crank pin for taper and out-of-round as shown in the illustration.

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

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

Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown the illustration.

Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration.

Using a screwdriver, pry out the main bearing caps. Remove the 5 main bearing caps and lower bearings.

Lay a strip of Plastigage across each journal.

Examine the front marks and numbers, and install the bearing caps on the cylinder block.

Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

Temporarily install the 10 main bearing cap bolts to the outside positions.

Step 1:

1. Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.

   Torque:

   for inside position

   61 N*m  { 622 kgf*cm, 45 ft.*lbf }

   for outside position

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

   If any of the main bearing cap bolts does not meet the specified torque, replace it.

   Note

   Do not turn the crankshaft.

Step 2:

1. Mark the front of the bearing cap bolts with paint.

2. Tighten the bearing cap bolts another 90° in the order shown in step 1.

3. Check that the painted marks are now at a 90° angle to the front.

Install and uniformly tighten the 10 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration.

Torque:

45 N*m  { 459 kgf*cm, 33 ft.*lbf }

Measure the plastigage at its widest point.

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

• Example:

  Cylinder block "07" + Crankshaft "06" = Total number 13 (Use upper bearing "6" and lower bearing "7")

Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.

If the diameter is less than the minimum, replace the bolt.