CYLINDER BLOCK INSPECTION

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. Install the connecting rod cap.

      Click here

    2. A0028WO

      Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard Thrust Clearance
      0.15 to 0.40 mm (0.00591 to 0.0157 in.)
      Maximum Thrust Clearance
      0.50 mm (0.0197 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. Clean the crank pin and connecting rod bearing.

    2. Check the crank pin and connecting rod bearing for pitting or scratches.

    3. A002CIIC03
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    4. A0027WGC03
      *a Front Mark
      B003ZIE Engine Front

      Ensure that the front mark of the connecting rod cap is facing forward.

    5. Install the connecting rod cap with the 2 bolts.

      Click here

      Note

      Do not turn the crankshaft.

    6. Remove the 2 bolts and connecting rod cap.

      Click here

    7. A002ADKC04
      *a Plastigage
      *b Mark 1, 2, 3, or 4

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.045 to 0.067 mm (0.00177 to 0.00264 in.)
      Maximum Oil Clearance
      0.070 mm (0.00276 in.)

      If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

      Tech Tips

      If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 4 sizes of standard connecting rod bearings, marked "1", "2", "3" or "4" accordingly.

      Standard Connecting Rod Diameter
      Mark Specified Condition
      1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
      2 56.007 to 56.012 mm (2.20500 to 2.20519 in.)
      3 56.013 to 56.018 mm (2.20523 to 2.20543 in.)
      4 56.019 to 56.024 mm (2.20547 to 2.20566 in.)
      Standard Connecting Rod Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.481 to 1.484 mm (0.05831 to 0.05843 in.)
      2 1.484 to 1.487 mm (0.05843 to 0.05854 in.)
      3 1.487 to 1.490 mm (0.05854 to 0.05866 in.)
      4 1.490 to 1.493 mm (0.05866 to 0.05878 in.)
      Standard Crankshaft Pin Diameter
      52.992 to 53.000 mm (2.0863 to 2.0866 in.)

      Note

      Completely remove the Plastigage after the measurement.

  3. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A002BDJ

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

      Maximum Warpage
      0.07 mm (0.00276 in.)

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

  4. INSPECT CYLINDER BORE


    1. A0027K4C04
      *a Thrust Direction
      *b Axial Direction
      *c 10 mm (0.394 in.)
      *d Center
      B003ZIE Front

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

      Reference Diameter (New Parts)
      94.000 to 94.012 mm (3.7008 to 3.7013 in.)
      Maximum Diameter
      94.13 mm (3.7059 in.)

      If the average diameter of 4 positions is more than the maximum, replace the cylinder block sub-assembly.

  5. INSPECT PISTON


    1. A002C98C04
      *a Distance

      Using a micrometer, measure the piston diameter at a right angle to the piston center line where the distance from the bottom of the piston is as specified.

      Distance
      9.8 mm (0.3858 in.)
      Reference Diameter (New Parts)
      93.960 to 93.980 mm (3.6992 to 3.7000 in.)
      Minimum Diameter
      93.830 mm (3.6941 in.)

      If the piston diameter is less than the minimum, replace the piston and piston pin as a set.

  6. 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.

      Reference Oil Clearance (New Parts)
      0.020 to 0.052 mm (0.000787 to 0.00205 in.)
      Maximum Oil Clearance
      0.060 mm (0.00236 in.)

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

  7. INSPECT RING GROOVE CLEARANCE


    1. A002C04

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

      Standard Ring Groove Clearance
      Item Specified Condition
      No. 1 compression ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
      No. 2 compression ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
      Oil ring 0.070 to 0.150 mm (0.00276 to 0.00591 in.)

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

  8. INSPECT PISTON PIN OIL CLEARANCE


    1. A002A48

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

      Standard Piston Pin Hole Inside Diameter
      Mark Specified Condition
      A 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
      B 22.004 to 22.007 mm (0.8663 to 0.8664 in.)
      C 22.007 to 22.010 mm (0.8664 to 0.8665 in.)
    2. A0027WJN06
      *1 5.0 mm (0.197 in.)
      *2 28 mm (1.10 in.)

      Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter
      Mark Specified Condition
      A 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
      B 22.000 to 22.003 mm (0.8661 to 0.8663 in.)
      C 22.003 to 22.006 mm (0.8663 to 0.8664 in.)

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

      Standard Oil Clearance
      0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
      Maximum Oil Clearance
      0.015 mm (0.000591 in.)

      If the oil clearance is more than the maximum, replace the piston and piston pin as a set.

    4. A0029E4

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

      Standard Bushing Inside Diameter
      Mark Specified Condition
      A 22.005 to 22.008 mm (0.86634 to 0.86645 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.)
    5. A002BSMC04
      *a Front Mark
      *b Piston Pin Hole Inside Diameter Mark
      *c Connecting Rod Bushing Inside Diameter Mark

      Subtract the piston pin diameter measurement from the bushing 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.)

      If the oil clearance is more than the maximum, replace the bushing. If necessary, replace the connecting rod sub-assembly and piston pin as a set.

  9. INSPECT PISTON RING END GAP


    1. Insert the piston ring into the cylinder bore.

    2. A002BUMC06
      *1 Piston Ring

      Using a piston, push in the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.

    3. A002AA1

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 compression ring 0.22 to 0.32 mm (0.00866 to 0.0126 in.)
      No. 2 compression ring 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
      Oil ring 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 compression ring 0.50 mm (0.0197 in.)
      No. 2 compression ring 0.85 mm (0.0335 in.)
      Oil ring 0.60 mm (0.0236 in.)

      If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block sub-assembly.

  10. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. Install the crankshaft bearing cap.

      Click here

    2. A002CGK

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard Thrust Clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum Thrust Clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the crankshaft thrust washer set. If necessary, replace the crankshaft.

      Standard Thrust Washer Thickness
      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

  11. INSPECT CONNECTING ROD SUB-ASSEMBLY


    1. A002BJ0

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


      1. Check for misalignment.

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

        If the misalignment is more than the maximum, replace the connecting rod sub-assembly.

      2. A0028LRE01

        Check for twist.

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

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

  12. INSPECT CONNECTING ROD BOLT


    1. A0027GKC30
      *a Measurement Area

      Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration.

      Standard Diameter
      7.2 to 7.3 mm (0.283 to 0.287 in.)
      Minimum Diameter
      7.0 mm (0.276 in.)

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

      Tech Tips


      • Diameter measurements should be done at several points.


      • If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.


      • If there is any thread deformation, replace the connecting rod bolt with a new one.

  13. INSPECT CRANKSHAFT


    1. Inspect for runout.


      1. Clean the crank journal.

      2. Place the crankshaft on V-blocks.

      3. A002B0G

        Using a dial indicator, measure the runout at the center of each journal.

        Maximum Runout
        0.06 mm (0.00236 in.)

        If the runout is more than the maximum, replace the crankshaft.

    2. Inspect the main journals.


      1. A002B8G

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

        Standard Journal Diameter
        60.988 to 61.000 mm (2.4011 to 2.4016 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 (0.000787 in.)

        If the taper or out-of-round is more than the maximum, replace the crankshaft.

    3. Inspect the crank pin.


      1. A002ALJ

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

        Standard Crank Pin Diameter
        52.992 to 53.000 mm (2.0863 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 (0.000787 in.)

        If the taper or out-of-round is more than the maximum, replace the crankshaft.

  14. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Check the crank journal and crankshaft bearing for pitting or scratches.

    2. Install the crankshaft bearings.

      Click here

    3. Place the crankshaft on the cylinder block sub-assembly.

    4. A0028YIC07
      *a Plastigage

      Lay a strip of Plastigage across each journal.

    5. Confirm the front marks and numbers, and install the crankshaft bearing caps on the cylinder block sub-assembly.

      Tech Tips

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

    6. Install the crankshaft bearing caps.

      Click here

      Note

      Do not turn the crankshaft.

    7. Remove the crankshaft bearing caps.

      Click here

    8. A0027KAC03
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.026 to 0.047 mm (0.00102 to 0.00185 in.)
      Maximum Oil Clearance
      0.050 mm (0.00197 in.)

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

      Note

      Completely remove the Plastigage after the measurement.

    9. for Crankshaft Bearings (except Part No. 11701-31100 and 11071-31060):


      1. If replacing a crankshaft bearing, select a new one with 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 sub-assembly and crankshaft. Then refer to the following table for the appropriate crankshaft bearing number. There are 5 sizes of standard crankshaft bearings, marked "1", "2", "3", "4" or "5" accordingly.

        A0029DVC09
        *a Number Mark *b No. 2 and No. 3 Crankshaft Bearing
        *c No. 1 and No. 4 Crankshaft Bearing *d No. 1
        *e No. 2 *f No. 3
        *g No. 4 *h 21.0 mm (0.827 in.)
        *i 18.0 mm (0.709 in.) - -
        Crankshaft Bearings
        Cylinder block sub-assembly+ Crankshaft 0 - 5 6 - 11 12 - 17 18 - 23 24 - 28
        Crankshaft bearing to be used "1" "2" "3" "4" "5"

        Tech Tips

        EXAMPLE: Cylinder block sub-assembly "11" + Crankshaft "06" = Total number 17 (Use bearing "3")

        Crankshaft Main Journal Diameter
        Mark Diameter
        "00" 60.999 to 61.000 mm (2.40153 to 2.40157 in.)
        "01" 60.998 to 60.999 mm (2.40149 to 2.40153 in.)
        "02" 60.997 to 60.998 mm (2.40145 to 2.40149 in.)
        "03" 60.996 to 60.997 mm (2.40141 to 2.40145 in.)
        "04" 60.995 to 60.996 mm (2.40137 to 2.40141 in.)
        "05" 60.994 to 60.995 mm (2.40133 to 2.40137 in.)
        "06" 60.993 to 60.994 mm (2.40129 to 2.40133 in.)
        "07" 60.992 to 60.993 mm (2.40126 to 2.40129 in.)
        "08" 60.991 to 60.992 mm (2.40122 to 2.40126 in.)
        "09" 60.990 to 60.991 mm (2.40118 to 2.40122 in.)
        "10" 60.989 to 60.990 mm (2.40114 to 2.40118 in.)
        "11" 60.988 to 60.989 mm (2.40110 to 2.40114 in.)
        Standard Upper Crankshaft Bearing Center Wall Thickness (No. 1 and No. 4 journal)
        Mark Specified Condition
        "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
        "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
        "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
        "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
        "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.)
        Standard Lower Crankshaft Bearing Center Wall Thickness (No. 1 and No. 4 journal)
        Mark Specified Condition
        "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
        "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
        "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
        "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
        "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.)
        Standard Upper Crankshaft Bearing Center Wall Thickness (No. 2 and No. 3 journal)
        Mark Specified Condition
        "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
        "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
        "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
        "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
        "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.)
        Standard Lower Crankshaft Bearing Center Wall Thickness (No. 2 and No. 3 journal)
        Mark Specified Condition
        "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
        "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
        "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
        "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
        "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.)

    10. for Crankshaft Bearings (Part No. 11701-31100 and 11071-31060):


      1. If replacing a crankshaft bearing, select a new one with 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 sub-assembly and crankshaft. Then refer to the following table for the appropriate crankshaft bearing number. There are 5 sizes of standard crankshaft bearings, marked "1", "2", "3", "4" or "5" accordingly.

        A0029DVC09
        *a Number Mark *b No. 2 and No. 3 Crankshaft Bearing
        *c No. 1 and No. 4 Crankshaft Bearing *d No. 1
        *e No. 2 *f No. 3
        *g No. 4 *h 21.0 mm (0.827 in.)
        *i 18.0 mm (0.709 in.) - -
        Crankshaft Bearings
        Cylinder block sub-assembly+ Crankshaft Upper crankshaft bearing to be used Lower crankshaft bearing to be used
        0 - 3 "1" "1"
        4 - 6 "1" "2"
        7 - 9 "2" "2"
        10 - 12 "2" "3"
        13 - 15 "3" "3"
        16 - 18 "3" "4"
        19 - 21 "4" "4"
        22 - 24 "4" "5"
        25 - 28 "5" "5"

        Tech Tips

        EXAMPLE: Cylinder block sub-assembly "12" + Crankshaft "06" = Total number 18 (Use upper bearing "3" and lower bearing "4")

        Crankshaft Main Journal Diameter
        Mark Diameter
        "00" 60.999 to 61.000 mm (2.40153 to 2.40157 in.)
        "01" 60.998 to 60.999 mm (2.40149 to 2.40153 in.)
        "02" 60.997 to 60.998 mm (2.40145 to 2.40149 in.)
        "03" 60.996 to 60.997 mm (2.40141 to 2.40145 in.)
        "04" 60.995 to 60.996 mm (2.40137 to 2.40141 in.)
        "05" 60.994 to 60.995 mm (2.40133 to 2.40137 in.)
        "06" 60.993 to 60.994 mm (2.40129 to 2.40133 in.)
        "07" 60.992 to 60.993 mm (2.40126 to 2.40129 in.)
        "08" 60.991 to 60.992 mm (2.40122 to 2.40126 in.)
        "09" 60.990 to 60.991 mm (2.40118 to 2.40122 in.)
        "10" 60.989 to 60.990 mm (2.40114 to 2.40118 in.)
        "11" 60.988 to 60.989 mm (2.40110 to 2.40114 in.)
        Standard Upper Crankshaft Bearing Center Wall Thickness (No. 1 and No. 4 journal)
        Mark Specified Condition
        "1" 2.497 to 2.500 mm (0.09831 to 0.09843 in.)
        "2" 2.501 to 2.503 mm (0.09846 to 0.09854 in.)
        "3" 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
        "4" 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
        "5" 2.510 to 2.512 mm (0.09882 to 0.09890 in.)
        Standard Lower Crankshaft Bearing Center Wall Thickness (No. 1 and No. 4 journal)
        Mark Specified Condition
        "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
        "2" 2.482 to 2.484 mm (0.09772 to 0.09780 in.)
        "3" 2.485 to 2.487 mm (0.09783 to 0.09791 in.)
        "4" 2.488 to 2.490 mm (0.09795 to 0.09803 in.)
        "5" 2.491 to 2.493 mm (0.09807 to 0.09815 in.)
        Standard Upper Crankshaft Bearing Center Wall Thickness (No. 2 and No. 3 journal)
        Mark Specified Condition
        "1" 2.476 to 2.479 mm (0.09748 to 0.09760 in.)
        "2" 2.480 to 2.482 mm (0.09764 to 0.09772 in.)
        "3" 2.483 to 2.485 mm (0.09776 to 0.09783 in.)
        "4" 2.486 to 2.488 mm (0.09787 to 0.09795 in.)
        "5" 2.489 to 2.491 mm (0.09799 to 0.09807 in.)
        Standard Lower Crankshaft Bearing Center Wall Thickness (No. 2 and No. 3 journal)
        Mark Specified Condition
        "1" 2.493 to 2.496 mm (0.09815 to 0.09827 in.)
        "2" 2.497 to 2.499 mm (0.09831 to 0.09839 in.)
        "3" 2.500 to 2.502 mm (0.09843 to 0.09850 in.)
        "4" 2.503 to 2.505 mm (0.09854 to 0.09862 in.)
        "5" 2.506 to 2.508 mm (0.09866 to 0.09874 in.)

  15. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A00278SC03
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard Diameter
      10.8 to 11.0 mm (0.4252 to 0.4331 in.)
      Minimum Diameter
      10.7 mm (0.4213 in.)
      Measurement Point (Distance from the Seat)
      40 mm (1.57 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage.


      • If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.

  16. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Check the No. 1 oil nozzle sub-assemblies for damage or clogs.

      Tech Tips

      If there is damage or clogs, replace the No. 1 oil nozzle sub-assembly.