CYLINDER BLOCK INSPECTION


  1. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A015ZDS

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

      If stuck, replace the No. 1 oil nozzle sub-assembly.

    2. A01623SE01

      While covering A, apply air into B. Then check the No. 1 oil nozzle sub-assembly for damage or clogging.

      If there is an air leak, clean or replace the No. 1 oil nozzle sub-assembly.

      Tech Tips

      Cover B and apply air into A. Perform the check again.

    3. A015ZONE01

      Push the check valve while covering A, and apply air into B. Check that air passes through the No. 1 oil nozzle sub-assembly.

      If air cannot pass through, clean or replace the No. 1 oil nozzle sub-assembly.

      Tech Tips

      Cover B and, while pushing the check valve, apply air into A. Perform the check again.

  2. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A0163HX

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

      Maximum warpage
      0.05 mm (0.00197 in.)

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

    2. A0163GI

      Visually check the cylinder for vertical scratches.

      If deep scratches are present, rebore all 8 cylinders.

      If necessary, replace the cylinder block subassembly.

  3. INSPECT CYLINDER BORE


    1. A015YKUE04

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

      Standard diameter
      94.000 to 94.012 mm (3.7008 to 3.7013 in.)
      Maximum diameter
      94.200 mm (3.7087 in.)

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

  4. INSPECT PISTON SUB-ASSEMBLY WITH PIN


    1. A016022E01

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

      Standard diameter
      93.980 to 93.990 mm (3.7000 to 3.7004 in.)
      Minimum diameter
      93.830 mm (3.6941 in.)

  5. INSPECT PISTON OIL CLEARANCE


    1. Measure the cylinder bore diameter in the thrust direction.

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

      Standard oil clearance
      0.010 to 0.032 mm (0.000394 to 0.00126 in.)
      Maximum oil clearance
      0.370 mm (0.0146 in.)

      If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly.

  6. INSPECT RING GROOVE CLEARANCE


    1. A015YJR

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

      Standard Ring Groove Clearance
      Item Specified Condition
      No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
      No. 2 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
      Oil 0.020 to 0.070 mm (0.000787 to 0.00276 in.)

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

  7. INSPECT PISTON RING END GAP


    1. Insert the piston ring into the cylinder bore.

    2. A0160CFE01

      Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.36 in.) from the top of the cylinder block.

    3. A015ZH2

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 0.23 to 0.33 mm (0.00906 to 0.0130 in.)
      No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
      Oil 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 0.40 mm (0.0157 in.)
      No. 2 0.50 mm (0.0197 in.)
      Oil 0.45 mm (0.0177 in.)

      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 sub-assembly.

  8. INSPECT PISTON PIN OIL CLEARANCE


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

      A015ZK3E01
    2. A0160O1

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

      Standard Piston Pin Hole Inside Diameter
      Mark Specified Condition
      A 21.998 to 22.001 mm (0.86606 to 0.86618 in.)
      B 22.002 to 22.004 mm (0.86622 to 0.86629 in.)
      C 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
    3. A01638BE08

      Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter
      Mark Specified Condition
      A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
      B 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
      C 22.004 to 22.006 mm (0.86629 to 0.86638 in.)

    4. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.

      Standard oil clearance
      -0.002 to 0.004 mm (-0.0000787 to 0.000158 in.)
      Maximum oil clearance
      0.015 mm (0.000591 in.)

      Tech Tips

      If the oil clearance is greater than the maximum, replace the piston with pin sub-assembly.

    5. A015ZX8

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

      Standard Bush Inside Diameter
      Mark Specified Condition
      A 22.005 to 22.008 mm (0.86634 to 0.86646 in.)
      B 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
      C 22.012 to 22.014 mm (0.86661 to 0.86669 in.)

    6. Subtract the piston pin diameter measurement from the bush inside diameter measurement.

      Standard oil clearance
      0.005 to 0.011 mm (0.000197 to 0.000433 in.)
      Maximum oil clearance
      0.030 mm (0.00118 in.)

      Tech Tips

      If the oil clearance is greater than the maximum, replace the piston with pin sub-assembly.

  9. INSPECT CONNECTING ROD SUB-ASSEMBLY


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


      1. A0162LR

        Check for bend.

        Maximum bend
        0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

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

      2. A0163JS

        Check for twist.

        Maximum twist
        0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

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

  10. INSPECT CONNECTING ROD BOLT


    1. A016173E03

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

      Standard diameter
      8.5 to 8.6 mm (0.335 to 0.339 in.)
      Minimum diameter
      8.3 mm (0.327 in.)

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

  11. INSPECT CRANKSHAFT


    1. A015ZC9

      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
        0.01 mm (0.000394 in.)

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

    2. A0162YJ

      Inspect the main journals.


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

        Standard journal diameter
        66.988 to 67.000 mm (2.63731 to 2.63779 in.)

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

    3. A015ZTH

      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 (2.08590 to 2.08661 in.)

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

  12. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Clean each main journal and bearing.

    2. Check each main journal and bearing for pitting and scratches.

      Tech Tips

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearing.

    3. Install the crankshaft bearing.

      Tech Tips

      Click here.

    4. Install the crankshaft thrust washer set.

      Tech Tips

      Click here.

    5. Place the crankshaft on the cylinder block.

    6. A0161G2E01

      Lay a strip of Plastigage across each journal.

    7. A01623VE01

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

      Tech Tips

      A number is marked on each main bearing cap to indicate the installation position.

    8. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

    9. Place the crankshaft bearing caps onto the cylinder block.

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

    11. A015Z15E01

      Insert the main bearing caps by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal bearing cap bolts as a guide.

      Bolt length
      91 mm (3.58 in.)
    12. A016196

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

    13. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts.

    14. A015ZV3E01

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

      Bolt length
      79.5 mm (3.13 in.)

      Tech Tips

      Tighten the main bearing cap bolts in 2 progressive steps.

    15. A015ZHVE02

      Step 1:


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

        Torque:
        61 N*m  { 622 kgf*cm, 45 ft.*lbf, for inside position }
        27 N*m  { 275 kgf*cm, 20 ft.*lbf, for outside position }

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

        Note

        Do not turn the crankshaft.

    16. A0163BWE01

      Step 2:


      1. Mark the front of each bearing cap bolt 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.

    17. A015ZZBE01

      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 }

    18. Remove the 30 bolts and bearing caps.

    19. A016011E01
      A015Z2PE02

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Number Mark Specified Condition
      No. 1 and No. 5 journal 0.017 to 0.030 mm (0.000669 to 0.00118 in.)
      Other journals 0.024 to 0.037 mm (0.000945 to 0.00146 in.)
      Maximum Oil Clearance
      Number Mark Specified Condition
      No. 1 and No. 5 journal 0.050 mm (0.00197 in.)
      Other journals 0.060 mm (0.00236 in.)

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

      Tech Tips

      If replacing a crankshaft bearing, replace it with one having the same number. If the number of the crankshaft bearing cannot be determined, select the correct crankshaft bearing by adding together the numbers imprinted on the cylinder block and crankshaft. Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For other position bearings, use bearing marked 3, 4, 5, 6, 7 and 8.


      • Example:

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

      Standard Crankshaft Main Journal Diameter
      Number Mark Specified Condition
      00 66.999 to 67.000 mm (2.63775 to 2.63779 in.)
      01 66.998 to 66.999 mm (2.63771 to 2.63775 in.)
      02 66.997 to 66.998 mm (2.63767 to 2.63771 in.)
      03 66.996 to 66.997 mm (2.63763 to 2.63767 in.)
      04 66.995 to 66.996 mm (2.63759 to 2.63763 in.)
      05 66.994 to 66.995 mm (2.63755 to 2.63759 in.)
      06 66.993 to 66.994 mm (2.63751 to 2.63755 in.)
      07 66.992 to 66.993 mm (2.63748 to 2.63751 in.)
      08 66.991 to 66.992 mm (2.63744 to 2.63748 in.)
      09 66.990 to 66.991 mm (2.63740 to 2.63744 in.)
      10 66.989 to 66.990 mm (2.63736 to 2.63740 in.)
      11 66.988 to 66.989 mm (2.63732 to 2.63736 in.)
      Standard Bearing Center Wall Thickness for No. 1 and No. 5 Journals
      (A) + (B) Upper Bearing Lower Bearing
      Number Mark Specified Condition Number Mark Specified Condition
      00 to 02 4 2.501 to 2.504 mm (0.0985 to 0.0986 in.) 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      03 to 05 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.) 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      06 to 08 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.) 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      09 to 11 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.) 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      12 to 14 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.) 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      15 to 17 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.) 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      18 to 20 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.) 8 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
      21 to 23 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.) 8 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
      24 to 26 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.) 9 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
      27 to 28 9 2.516 to 2.519 mm (0.0991 to 0.0992 in.) 9 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
      Standard Bearing Center Wall Thickness for Other Journals
      (A) + (B) Upper Bearing Lower Bearing
      Number Mark Specified Condition Number Mark Specified Condition
      00 to 02 3 2.482 to 2.485 mm (0.0977 to 0.0978 in.) 4 2.501 to 2.504 mm (0.0985 to 0.0986 in.)
      03 to 05 4 2.485 to 2.488 mm (0.0978 to 0.0980 in.) 4 2.501 to 2.504 mm (0.0985 to 0.0986 in.)
      06 to 08 4 2.485 to 2.488 mm (0.0978 to 0.0980 in.) 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.)
      09 to 11 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.) 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.)
      12 to 14 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.) 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.)
      15 to 17 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.) 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.)
      18 to 20 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.) 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.)
      21 to 23 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.) 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.)
      24 to 26 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.) 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.)
      27 to 28 8 2.497 to 2.500 mm (0.0983 to 0.0984 in.) 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.)

    20. Completely remove the Plastigage.

  13. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A015ZRGE01

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

      Standard diameter
      10.8 to 11.0 mm (0.425 to 0.433 in.) for bolt A
      9.8 to 10.0 mm (0.386 to 0.394 in.) for bolt B
      Minimum diameter
      10.7 mm (0.421 in.) for bolt A
      9.7 mm (0.382 in.) for bolt B
      Measuring point
      47 mm (1.85 in.)

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