CYLINDER BLOCK INSPECTION

PROCEDURE


  1. CLEAN CYLINDER BLOCK SUB-ASSEMBLY


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

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

      Note

      If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block sub-assembly. Always wash the cylinder block sub-assembly at a temperature of 45°C (113°F) or less.

  2. INSPECT CYLINDER BLOCK FOR FLATNESS


    1. B003PVP

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

      Maximum warpage
      0.05 mm (0.00197 in.)

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

  3. INSPECT CYLINDER BORE


    1. B003OGLC01
      *a Engine Front
      *b Thrust Direction
      *c Axial Direction
      *d Center
      *e 10 mm (0.394 in.)

      Using a cylinder gauge, measure the cylinder bore diameter at 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
      94.132 mm (3.7060 in.)

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

  4. INSPECT PISTON DIAMETER


    1. B003K7YC01
      *a 27.7 mm (1.09 in.)

      Using a micrometer, measure the piston diameter at a right angle to the piston pin center line, 27.7 mm (1.09 in.) from the piston head.

      Reference piston diameter (new part)
      93.926 to 93.936 mm (3.6979 to 3.6983 in.)

  5. INSPECT PISTON OIL CLEARANCE


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

      Reference oil clearance (new part)
      0.064 to 0.086 mm (0.00252 to 0.00339 in.)
      Maximum oil clearance
      0.13 mm (0.00512 in.)

      If the oil clearance is more than the maximum, replace all 6 pistons. If necessary, replace the cylinder block sub-assembly.

  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 0.02 to 0.07 mm (0.000787 to 0.00276 in.)
      No. 2 compression ring 0.02 to 0.06 mm (0.000787 to 0.00236 in.)
      Oil ring 0.07 to 0.15 mm (0.00276 to 0.00591 in.)

      If the clearance is not as specified, replace the piston with pin sub-assembly and piston ring set.

  7. INSPECT PISTON RING END GAP


    1. 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 sub-assembly.

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

      Standard End Gap
      Item Specified Condition
      No. 1 compression ring 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
      No. 2 compression ring 0.40 to 0.50 mm (0.0157 to 0.0197 in.)
      Oil ring (side rail) 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 compression ring 1.0 mm (0.0394 in.)
      No. 2 compression ring 1.1 mm (0.0433 in.)
      Oil ring (side rail) 1.0 mm (0.0394 in.)

      If the end gap is more than the maximum, replace the piston ring set.

  8. INSPECT PISTON PIN OIL CLEARANCE


    1. Check each mark on the piston and connecting rod sub-assembly.

      B003R5WC01
      *a Inside Diameter Mark *b Front Mark
    2. B003OD5

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

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

    3. Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter
      Item Specified Condition
      Mark A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
      Mark B 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
      Mark C 22.004 to 22.006 mm (0.86630 to 0.86638 in.)
      B003SF9C01
      *a 5.0 mm (0.197 in.) *b 28 mm (1.10 in.)

    4. 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
      0.040 mm (0.00157 in.)

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

    5. B003K9D

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

      Standard Bush Inside Diameter
      Item Specified Condition
      Mark A 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
      Mark B 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
      Mark 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
      0.050 mm (0.00197 in.)

      If the oil clearance is more than the maximum, replace the connecting rod sub-assembly and piston with pin sub-assembly.

  9. INSPECT CRANKSHAFT


    1. B003P6S

      Using a dial indicator and V-blocks, measure the runout as shown in the illustration.

      Maximum circle runout
      0.06 mm (0.00236 in.)

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

    2. B003O1J

      Using a micrometer, measure the diameter of each main journal as shown in the illustration.

      Standard diameter
      71.988 to 72.000 mm (2.8342 to 2.8346 in.)

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

    3. Inspect each main journal for taper and out-of-round.

      Maximum taper and out-of-round
      0.02 mm (0.000787 in.)

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

    4. B003NO7

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

      Standard diameter
      55.992 to 56.000 mm (2.2044 to 2.2047 in.)

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

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

  10. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Install the crankshaft bearing.

      Click here

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

    3. Install the crankshaft thrust washer.

      Click here

    4. B003RXBC01
      *a Plastigage

      Lay a strip of Plastigage across each journal.

      Note

      Do not turn the crankshaft.

    5. Install the crankshaft bearing cap.

      Click here

    6. Remove the crankshaft bearing cap.

      Click here

    7. B003MP5C01
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.018 to 0.030 mm (0.000709 to 0.00118 in.)
      Maximum clearance
      0.046 mm (0.00181 in.)

      Note

      After checking, completely remove the Plastigage.

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

      B003JFGC01
      *a No. 1 *b No. 2
      *c No. 3 *d No. 4
      *e Number Mark - -

      Tech Tips


      • If replacing a bearing, replace it with one that has the same number.

      • If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number.

        Example: Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3")

      • There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

      New Bearing
      Use Bearing 1 2 3 4 5
      Cylinder Block (A) + Crankshaft (B) 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28
      Cylinder Block Main Journal Bore Diameter (A)
      Item Specified Condition
      Mark 00 77.000 mm (3.03149 in.)
      Mark 01 77.001 mm (3.03153 in.)
      Mark 02 77.002 mm (3.03157 in.)
      Mark 03 77.003 mm (3.03161 in.)
      Mark 04 77.004 mm (3.03165 in.)
      Mark 05 77.005 mm (3.03169 in.)
      Mark 06 77.006 mm (3.03173 in.)
      Mark 07 77.007 mm (3.03177 in.)
      Mark 08 77.008 mm (3.03180 in.)
      Mark 09 77.009 mm (3.03184 in.)
      Mark 10 77.010 mm (3.03188 in.)
      Mark 11 77.011 mm (3.03192 in.)
      Mark 12 77.012 mm (3.03196 in.)
      Mark 13 77.013 mm (3.03200 in.)
      Mark 14 77.014 mm (3.03204 in.)
      Mark 15 77.015 mm (3.03208 in.)
      Mark 16 77.016 mm (3.03212 in.)
      Crankshaft Main Journal Diameter (B)
      Item Specified Condition
      Mark 00 71.999 to 72.000 mm (2.83460 to 2.83464 in.)
      Mark 01 71.998 to 71.999 mm (2.83456 to 2.83460 in.)
      Mark 02 71.997 to 71.998 mm (2.83452 to 2.83456 in.)
      Mark 03 71.996 to 71.997 mm (2.83448 to 2.83452 in.)
      Mark 04 71.995 to 71.996 mm (2.83444 to 2.83448 in.)
      Mark 05 71.994 to 71.995 mm (2.83440 to 2.83444 in.)
      Mark 06 71.993 to 71.994 mm (2.83436 to 2.83440 in.)
      Mark 07 71.992 to 71.993 mm (2.83433 to 2.83436 in.)
      Mark 08 71.991 to 71.992 mm (2.83429 to 2.83433 in.)
      Mark 09 71.990 to 71.991 mm (2.83425 to 2.83429 in.)
      Mark 10 71.989 to 71.990 mm (2.83421 to 2.83425 in.)
      Mark 11 71.988 to 71.989 mm (2.83417 to 2.83421 in.)
      Standard Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      Mark 2 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      Mark 3 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      Mark 4 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
      Mark 5 2.500 to 2.503 mm (0.0984 to 0.0985 in.)

    9. Remove the crankshaft.

      Click here

    10. Remove the crankshaft thrust washer.

      Click here

    11. Remove the crankshaft bearing.

      Click here

  11. INSPECT CONNECTING ROD SUB-ASSEMBLY


    1. B003NXD

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


      1. Check for bend.

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

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

      2. B003NWT

        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. Check that there is no damage or deformation on the threads of the connecting rod bolt.

      Tech Tips

      If there is any damage or deformation, replace the connecting rod bolt.

    2. B003JLTC06
      *a Measurement Area

      Using a vernier caliper, measure the diameter of the connecting rod bolt in 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.)

      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.

  13. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. Check that there is no damage or deformation on the threads of the crankshaft bearing cap set bolt.

      Tech Tips

      If there is any damage or deformation, replace the crankshaft bearing cap set bolt.

    2. B003KRFC03
      *a Measuring Area
      *b 60 mm (2.36 in.)

      Using a vernier caliper, measure the thread outside diameter of the crankshaft bearing cap set bolt in the measuring area.

      Standard diameter
      10.0 to 10.2 mm (0.394 to 0.402 in.)

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

  14. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B003MWJ

      Push the check valve with a pin to check if it is stuck. If stuck, replace the No. 1 oil nozzle sub-assembly.

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

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

    3. B003R0OE01

      While covering A, blow air into B. Check that air does not leak through C. Perform the check again while covering B and blowing air into A.

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

    4. B003RJVE01

      Push the check valve while covering A, and blow air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and blowing air into A.

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