CYLINDER BLOCK INSPECTION

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A003OV9

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

      Standard Thrust Clearance
      0.160 to 0.342 mm (0.00630 to 0.0135 in.)
      Maximum Thrust Clearance
      0.342 mm (0.0135 in.)

      Tech Tips

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE

    Tech Tips

    Using SST, install and alternately tighten the 2 connecting rod bolts in several steps.


    1. Remove the connecting rod bearing cap and connecting rod bearing.

      Click here

    2. Clean the crankshaft crank pin and connecting rod bearing.

    3. Check the crankshaft crank pin and connecting rod bearing for pitting and scratches.

      Tech Tips

      If the crank pin or upper connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.

    4. A003LFCC01
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    5. A003ORYC01
      *a Front Mark

      Check that the front mark of the connecting rod bearing cap is facing the correct direction, and install the connecting rod bearing cap to the connecting rod.

    6. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

    7. A003K8FN02

      Using SST, install and alternately tighten the 2 connecting rod bolts in several steps.

      SST
      09205-16011
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    8. A003OLUC01
      *a Paint Mark
      *b 90°
      B006IR6 Front of Engine

      Mark the front of each connecting rod bolt with paint.

    9. Tighten the connecting rod bolts 90° as shown in the illustration.

      Note

      Do not turn the crankshaft during the measurement.

    10. Remove the 2 connecting rod bolts and connecting rod bearing cap.

    11. A003NP5C01
      *a Plastigage
      *b 1, 2 or 3 Mark

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.014 to 0.038 mm (0.000551 to 0.00150 in.)
      Maximum Oil Clearance
      0.070 mm (0.00276 in.)

      Tech Tips


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

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

      Standard Connecting Rod Large End Bore Diameter
      Mark Specified Condition
      1 47.000 to 47.008 mm (1.85039 to 1.85070 in.)
      2 47.009 to 47.016 mm (1.85074 to 1.85102 in.)
      3 47.017 to 47.024 mm (1.85106 to 1.85133 in.)
      Standard Connecting Rod Bearing Thickness
      Mark Specified Condition
      1 1.489 to 1.493 mm (0.05862 to 0.05878 in.)
      2 1.494 to 1.497 mm (0.05882 to 0.05894 in.)
      3 1.498 to 1.501 mm (0.05898 to 0.05909 in.)
      Standard Crankshaft Pin Diameter
      43.992 to 44.000 mm (1.73197 to 1.73228 in.)

      Note

      Completely remove the Plastigage after the measurement.

  3. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A003NWP

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

      Standard Thrust Clearance
      0.04 to 0.14 mm (0.00157 to 0.00551 in.)
      Maximum Thrust Clearance
      0.18 mm (0.00709 in.)

      Tech Tips

      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.)

  4. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Check the crankshaft journals and crankshaft bearings for pitting and scratches.

    2. Install the crankshaft bearings.

      Click here

    3. Install the upper crankshaft thrust washers.

      Click here

    4. Clean each main journal and crankshaft bearing.

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

    6. A003OSVC02
      *a Plastigage

      Lay a strip of Plastigage across each journal.

    7. A003MK8C01
      *a Front Mark and Number

      Confirm the front marks and numbers, and place the 5 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.

    8. Install the crankshaft bearing caps.

      Click here

      Note

      Do not turn the crankshaft.

    9. Remove the crankshaft bearing caps.

      Click here

    10. Measure the Plastigage at its widest point.

      A003KKBC02
      *a No. 1 *b No. 2
      *c No. 3 *d No. 4
      *e No. 5 *f Plastigage
      *g Cylinder Block Number Mark *h Crankshaft Number Mark
      *i Diameter Mark - -
      Standard Oil Clearance
      0.014 to 0.038 mm (0.000551 to 0.001496 in.)

      Note

      Completely remove the Plastigage after the measurement.

    11. If replacing a crankshaft bearing, select a new one with the same number.

      Tech Tips


      • If the number of the crankshaft bearing cannot be determined, select the correct crankshaft bearing number 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 4 sizes of standard crankshaft bearings, marked "1", "2", "3" or "4" accordingly.

      • Example: Cylinder block "4" + Crankshaft "3" = Total number 7 (Use crankshaft bearing "3")

      Crankshaft Bearing
      Cylinder block sub-assembly + Crankshaft Crankshaft bearing to be used
      0 to 2 "1"
      3 to 5 "2"
      6 to 8 "3"
      9 to 11 "4"
      Standard Cylinder Block Journal Bore Diameter
      Mark Specified Condition
      0 52.000 to 52.002 mm (2.04724 to 2.04732 in.)
      1 52.003 to 52.004 mm (2.04736 to 2.04740 in.)
      2 52.005 to 52.006 mm (2.04744 to 2.04748 in.)
      3 52.007 to 52.009 mm (2.04752 to 2.04759 in.)
      4 52.010 to 52.011 mm (2.04763 to 2.04767 in.)
      5 52.012 to 52.013 mm (2.04771 to 2.04775 in.)
      6 52.014 to 52.016 mm (2.04779 to 2.04787 in.)
      Standard Crankshaft Journal Diameter
      Mark Specified Condition
      0 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
      1 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
      2 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
      3 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
      4 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
      5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
      Standard Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.991 to 1.994 mm (0.07839 to 0.07850 in.)
      2 1.995 to 1.997 mm (0.07854 to 0.07862 in.)
      3 1.998 to 2.000 mm (0.07866 to 0.07874 in.)
      4 2.001 to 2.003 mm (0.07878 to 0.07886 in.)

  5. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A003NWT

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

      Maximum Warpage
      0.05 mm (0.00197 in.)

      Tech Tips

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

  6. INSPECT CYLINDER BORE


    1. A003LBDC02
      *a Thrust Direction
      *b Axial Direction
      B006IR6 Front of Engine

      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)
      80.500 to 80.513 mm (3.16929 to 3.16980 in.)
      Maximum Diameter
      80.63 mm (3.17 in.)
      Measurement Position
      Measurement Position Cylinder Bore Position
      (A) 10 mm (0.394 in.) from top edge
      (B) 50 mm (1.97 in.) from top edge

      Tech Tips

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

  7. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A003M33C01
      *a Pin

      Push the check valve with a pin to check that it is not stuck.

      Tech Tips

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

    2. A003N1SN01

      Apply air into (A). Check that air does not leak through (B).

      Tech Tips

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

    3. A003LRQC01
      *a Pin

      Push the check valve with a pin while applying air into (A). Check that air passes through (B).

      Tech Tips

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

  8. INSPECT PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A003L61

      Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

      Tech Tips

      If abnormal movement is felt, replace the piston and piston pin as a set.

  9. INSPECT PISTON


    1. A003OQ8C01
      *a 9.0 mm

      Using a micrometer, measure the piston diameter at a position 9.0 mm (0.354 in.) from the bottom of the piston (refer to the illustration).

      Reference Piston Diameter (New Parts)
      80.473 to 80.503 mm (3.16822 to 3.16940 in.)

      Tech Tips

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

  10. INSPECT PISTON OIL CLEARANCE


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

      Reference Oil Clearance (New Parts)
      -0.003 to 0.040 mm (-0.000118 to 0.00157 in.)
      Maximum Oil Clearance
      0.08 mm (0.00315 in.)

      Tech Tips

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

  11. INSPECT RING GROOVE CLEARANCE


    1. A003MBM

      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 0.02 to 0.07 mm (0.000787 to 0.00276 in.)
      No. 2 Compression Ring 0.02 to 0.055 mm (0.000787 to 0.00217 in.)
      Oil Ring 0.07 to 0.13 mm (0.00276 to 0.00512 in.)

      Tech Tips

      If the groove clearance is not as specified, replace the piston and piston pin as a set.

  12. INSPECT PISTON RING END GAP


    1. A003LYAC01
      *a 50 mm

      Using a piston, push the piston ring a little beyond the bottom of the ring travel, 50 mm (1.97 in.) from the top of the cylinder block sub-assembly.

    2. A003P3S

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 Compression Ring 0.24 to 0.28 mm (0.00945 to 0.0110 in.)
      No. 2 Compression Ring 0.30 to 0.40 mm (0.0118 to 0.0157 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 0.5 mm (0.0197 in.)
      No. 2 Compression Ring 0.7 mm (0.0276 in.)
      Oil Ring 0.7 mm (0.0276 in.)

      Tech Tips

      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.

  13. INSPECT PISTON PIN OIL CLEARANCE

    Tech Tips

    When replacing the piston and piston pin with supply parts, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.


    1. A003LE4

      Using a caliper gauge, measure the piston pin bore diameter.

      Standard Piston Pin Bore Diameter
      20.006 to 20.015 mm (0.78764 to 0.78799 in.)
      Item Specified Condition
      Mark A 20.006 to 20.009 mm (0.78764 to 0.78775 in.)
      Mark B 20.010 to 20.012 mm (0.78779 to 0.78787 in.)
      Mark C 20.013 to 20.015 mm (0.78791 to 0.78799 in.)

      Tech Tips

      If the diameter is not as specified, replace the piston and piston pin as a set.

    2. A003LVNN02

      Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter
      20.004 to 20.013 mm (0.78756 to 0.78791 in.)
      Item Specified Condition
      Mark A 20.004 to 20.007 mm (0.78756 to 0.78768 in.)
      Mark B 20.008 to 20.010 mm (0.78771 to 0.78779 in.)
      Mark C 20.011 to 20.013 mm (0.78783 to 0.78791 in.)

      Tech Tips

      If the diameter is not as specified, replace the piston and piston pin as a set.

      Measurement Position
      Measurement Position Piston Pin Position
      a 5 mm (0.197 in.) from side edge
      b 25 mm (0.984 in.) from side edge
    3. A003O5R

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

      Standard Connecting Rod Small End Bush Bore Diameter
      20.012 to 20.021 mm (0.78787 to 0.78823 in.)
      Item Specified Condition
      Mark A 20.012 to 20.015 mm (0.78787 to 0.78799 in.)
      Mark B 20.016 to 20.018 mm (0.78803 to 0.78811 in.)
      Mark C 20.019 to 20.021 mm (0.78815 to 0.78823 in.)

      Tech Tips

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

    4. A003NTEC01
      *a Upper Side
      *b Lower Side
      *c Front Mark
      *d Piston Pin Bore Diameter Mark
      *e Connecting Rod Small End Bush Bore Diameter Mark

      Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.

      Standard Oil Clearance
      -0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)
      Maximum Oil Clearance
      0.010 mm (0.000394 in.)

      Tech Tips

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

    5. 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
      0.014 mm (0.000551 in.)

      Tech Tips

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

  14. INSPECT CONNECTING ROD BOLT


    1. A003NN1C02
      *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
      6.6 to 6.7 mm (0.260 to 0.264 in.)
      Minimum Diameter
      6.4 mm (0.252 in.)

      Note


      • 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.

      Tech Tips

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

  15. INSPECT CRANKSHAFT


    1. Inspect the runout.


      1. A003MFK

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

        Maximum Runout
        0.03 mm (0.00118 in.)

        Tech Tips

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

    2. Inspect the main journals.


      1. A003L5YN01

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

        Standard Diameter
        47.988 to 48.000 mm (1.88929 to 1.88976 in.)
        Standard Diameter (Reference)
        Mark Specified Condition
        0 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
        1 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
        2 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
        3 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
        4 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
        5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)

        Tech Tips

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

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

        Maximum Taper and Out-of-Round
        0.004 mm (0.000157 in.)

        Tech Tips

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

    3. Inspect the crank pins.


      1. A003M0C

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

        Standard Diameter
        43.992 to 44.000 mm (1.73197 to 1.73228 in.)

        Tech Tips

        If the diameter is not as specified, check the connecting rod oil clearance.

      2. Inspect each crank pin for taper and out-of-round.

        Maximum Taper and Out-of-Round
        0.004 mm (0.000157 in.)

        Tech Tips

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

  16. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A003NC9C01
      *a Measurement Length
      *b Measurement Area
      *c 55 mm (2.17 in.)

      Using a vernier caliper, measure the length of the crankshaft bearing cap set bolt from the seat to the end.

      Standard Length
      84.3 to 85.7 mm (3.32 to 3.37 in.)
      Maximum Length
      86.7 mm (3.41 in.)

      Note


      • If the length is greater than the maximum, replace the crankshaft bearing cap set bolt with a new one. 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.

    2. Using a vernier caliper, measure the minimum diameter of the threads at several points within the area shown in the illustration.

      Standard Diameter
      9.77 to 9.96 mm (0.385 to 0.392 in.)
      Minimum Diameter
      9.1 mm (0.358 in.)

      Note


      • Diameter measurements should be done at several points.

      • If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt with a new one. 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.