БЛОК ЦИЛИНДРОВ ПРОВЕРКА

PROCEDURE


  1. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A01L915

      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 more than the maximum, replace the cylinder block.

    2. Visually check the cylinders for vertical scratches.

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

  2. INSPECT CYLINDER BORE


    1. A01L9L1C05
      *a Thrust Direction
      *b Axial Direction
      *c 10 mm (0.394 in.)
      *d 70 mm (2.75 in.)
      B0027PX Front

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

      Reference value (new parts)
      85.990 to 86.003 mm (3.3854 to 3.3859 in.)
      Maximum diameter
      86.190 mm (3.3933 in.)

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

    2. A01LEIHC06
      *a Ridge Reamer

      Inspect the cylinder ridge.

      If the wear is less than 0.2 mm (0.00787 in.), using a ridge reamer, grind the top of the cylinder.

  3. CLEAN CYLINDER BLOCK


    1. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

    2. Using a soft brush and solvent, thoroughly clean the cylinder block.

  4. INSPECT PISTON DIAMETER


    1. A01L8YPC01
      *a Distance

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

      Distance
      11.6 mm (0.457 in.)
      Reference value (new parts)
      85.977 to 85.987 mm (3.3849 to 3.3853 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.

      Reference value (new parts)
      0.003 to 0.024 mm (0.000118 to 0.000945 in.)

      If the oil clearance is more than the standard, replace all the pistons and rebore all the cylinders. If necessary, replace the cylinder block.

  6. INSPECT RING GROOVE CLEARANCE


    1. 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 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 0.060 to 0.120 mm (0.00236 to 0.00472 in.)

      If the groove clearance is not as specified, replace the piston with pin.

  7. INSPECT 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, 110 mm (4.33 in.) from the top of the cylinder block.

    3. Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 compression ring 0.27 to 0.32 mm (0.0106 to 0.0126 in.)
      No. 2 compression ring 0.45 to 0.57 mm (0.0177 to 0.0224 in.)
      Oil ring 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 compression ring 0.90 mm (0.0354 in.)
      No. 2 compression ring 1.36 mm (0.0535 in.)
      Oil ring 0.75 mm (0.0295 in.)

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

  8. INSPECT PISTON PIN OIL CLEARANCE

    Tech Tips

    There is only 1 type of supply part for piston with pin sub-assembly.


    1. A01LBZKC01
      *a Front Mark
      *b Piston Pin Hole Inside Diameter Mark

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

      Standard Piston Pin Hole Inside Diameter
      Item Specified Condition
      A 22.001 to 22.004 mm (0.86618 to 0.86630 in.)
      B 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
      C 22.008 to 22.010 mm (0.86645 to 0.86653 in.)

      If the diameter is not as specified, replace the piston with pin.

    2. A01LFKFC01
      *a Piston Pin Hole Inside Diameter Mark

      Using a micrometer, measure the piston pin diameter.

      Measurement Position
      Measurement Position Piston Pin Position
      a 28 mm (1.10 in.)
      b 5.0 mm (0.197 in.)
      Standard Piston Pin Diameter
      Item 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 (0.86630 to 0.86638 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
      0.010 mm (0.000394 in.)

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

    4. A01LFMJC04
      *a Connecting Rod Bush Inside Diameter Mark
      *b Front Mark

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

      Standard Bush Inside Diameter
      Item 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.)

      If the diameter is not as specified, replace the connecting rod small end bush.

    5. Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement.

      Standard oil clearance
      0.005 to 0.011 mm (0.000197 to 0.000433 in.)
      Maximum oil clearance
      0.025 mm (0.000984 in.)

      If the oil clearance is more than the maximum, replace the connecting rod small end bush. If necessary, replace the connecting rod and piston pin as a set.

  9. INSPECT CONNECTING ROD SUB-ASSEMBLY


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


      1. A01LFCK

        Check for bend.

        Maximum bend
        0.03 mm (0.00118 in.) per 100 mm (3.94 in.)

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

      2. A01L9AP

        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.

  10. INSPECT CRANKSHAFT


    1. Inspect the 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
        0.03 mm (0.00118 in.)

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

    2. Inspect the main journals.


      1. A01L8R4C01
        *a No. 1
        *b No. 2
        *c No. 3
        *d No. 4
        *e No. 5

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

        Standard Journal Diameter
        Item Specified Condition
        No. 3 journal 59.981 to 59.994 mm (2.3615 to 2.3620 in.)
        Except No. 3 journal 59.987 to 60.000 mm (2.3617 to 2.3622 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
        0.005 mm (0.000197 in.)

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

    3. Inspect the crank pins.


      1. A01LE0D

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

        Standard diameter
        52.989 to 53.002 mm (2.086 to 2.087 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
        0.003 mm (0.000118 in.)

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

  11. INSPECT CRANKSHAFT OIL CLEARANCE

    Tech Tips


    • Keep the lower crankshaft bearings and crankshaft bearing caps together.

    • Arrange the thrust washers in the correct order.

    • Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.


    1. Clean each main journal and bearing.

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

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

    3. Install the crankshaft bearings and upper crankshaft thrust washers.

    4. Place the crankshaft on the cylinder block.

    5. A01L8UFC05
      *a Plastigage

      Lay a strip of Plastigage across each journal.

    6. Install the 5 crankshaft bearing caps with the 10 crankshaft bearing cap set bolts.

      Click here

      Note

      Do not turn the crankshaft.

    7. Remove the 10 crankshaft bearing cap set bolts and 5 crankshaft bearing caps.

      Click here

    8. Measure the Plastigage at its widest point.

      A01LE2YC01
      *a Plastigage *b No. 1 Journal
      *c No. 2 Journal *d No. 3 Journal
      *e No. 4 Journal *f No. 5 Journal
      *g Cylinder Block Journal Code *h Crankshaft Bearing Code
      *i Bearing Code Chart - -
      Standard Oil Clearance
      Item Specified Condition
      No. 3 journal 0.030 to 0.055 mm (0.00118 to 0.00217 in.)
      Other journals 0.024 to 0.049 mm (0.000945 to 0.00193 in.)
      Maximum oil clearance
      0.10 mm (0.00394 in.)

      • If the oil clearance is more than the maximum, replace the crankshaft bearing.

      • If replacing the cylinder block, measure the bearing standard clearance.

      • Check the cylinder block journal code and refer to the crankshaft bearing selection chart to select a bearing size.

      • (Example): When the cylinder block journal code is "D", select crankshaft bearing selection code "2" from the crankshaft bearing selection chart.

      Cylinder Block Main Journal Bore Diameter
      Item Specified Condition
      Mark A 64.004 to 64.006 mm (2.51984 to 2.51992 in.)
      Mark B 64.007 to 64.008 mm (2.51996 to 2.51999 in.)
      Mark C 64.009 to 64.010 mm (2.52003 to 2.52007 in.)
      Mark D 64.011 to 64.012 mm (2.52011 to 2.52015 in.)
      Mark E 64.013 to 64.014 mm (2.52019 to 2.52023 in.)
      Mark F 64.015 to 64.016 mm (2.52027 to 2.52031 in.)
      Mark G 64.017 to 64.018 mm (2.52035 to 2.52039 in.)
      Mark H 64.019 to 64.020 mm (2.52043 to 2.52047 in.)
      Mark J 64.021 to 64.022 mm (2.52051 to 2.52055 in.)
      Standard Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 1.987 to 1.990 mm (0.07823 to 0.07835 in.)
      Mark 2 1.991 to 1.993 mm (0.07839 to 0.07846 in.)
      Mark 3 1.994 to 1.996 mm (0.07850 to 0.07858 in.)

    9. Completely remove the Plastigage.

  12. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01L9FWC07
      B0027PX Push

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

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

    2. Push the check valve with a pin to check if it moves smoothly.

      If the check valve does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly.

    3. A01LCY3C06
      B0027PX Air

      Blow air into A. Check that air does not leak from B.

      If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

    4. A01LEUZC06
      B0027PX Air
      B0027QD Push

      Push the check valve while blowing air into A. Check that air passes through B.

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

  13. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A01L8HGC07
      *a Distance
      *b Measuring Area

      Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.

      Distance
      64 mm (2.52 in.)
      Standard diameter
      10.76 to 10.97 mm (0.424 to 0.432 in.)
      Minimum diameter
      10.66 mm (0.420 in.)

      If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt.

  14. INSPECT CONNECTING ROD BOLT


    1. A01L9PQC08
      *a Tension Portion

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

      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.