CYLINDER BLOCK INSPECTION


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A011AAU

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

      Standard thrust clearance
      0.16 to 0.36 mm (0.0063 to 0.0142 in.)
      Maximum thrust clearance
      0.36 mm (0.0142 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod sub-assembly.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A0117N5E01
      Text in Illustration
      *1 Matchmark

      Confirm that the matchmarks of the connecting rod sub-assembly and connecting rod cap are aligned.

    2. A0117G6E01

      Using SST, remove the 2 bolts and the connecting rod cap.

      SST
      09205-16011
    3. A011B9IE01
      Text in Illustration
      *1 Plastigage

      Clean the bearing and connecting rod sub-assembly end crank pin.

    4. Check that the bearing and crank pin are not excessively worn or scratched.

    5. Lay a strip of Plastigage across the crank pin.

    6. A0119FGE01
      Text in Illustration
      *1 Front Mark

      Check the front marks of the connecting rod sub-assembly and connecting rod cap, and then install the connecting rod cap onto the connecting rod sub-assembly.

    7. Apply a light coat of engine oil to the threads and contact surfaces of the bolts.

    8. A0117G6E01

      Using SST, temporarily tighten the bolts in several steps, and then retighten them to the specified torque.

      SST
      09205-16011
      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
    9. A011BV6E11
      Text in Illustration
      *1 Paint Mark

      Mark the front of the connecting cap bolts with paint.

    10. Retighten the cap bolts by 90° as shown in the illustration.

      Note

      Do not turn the crankshaft when measuring.

    11. A0117TP

      Remove the connecting rod cap, and then measure the Plastigage at its widest point.

      Standard oil clearance
      0.014 to 0.038 mm (0.0006 to 0.0015 in.)
      Maximum oil clearance
      0.065 mm (0.026 in.)

      Note

      Completely remove the Plastigage.

    12. A0118A8E02
      Text in Illustration
      *1 Front Mark
      *2 Number Mark

      If the clearance is greater than the maximum, select and install a replacement connecting rod bearing.

      Reference:
      Number Mark

      Connecting Rod

      External Diameter

      mm (in.)

      Center Bearing

      Thickness

      mm (in.)

      Oil Clearance

      mm (in.)
      1

      47.000 to 47.008

      (1.85039 to 1.85071)

      1.489 to 1.493

      (0.05862 to 0.05878)

      0.014 to 0.038

      (0.00055 to 0.00150)
      2

      47.009 to 47.016

      (1.85075 to 1.85102)

      1.494 to 1.497

      (0.05882 to 0.05894)

      		 ↑
      3

      47.017 to 47.024

      (1.85106 to 1.85134)

      1.498 to 1.501

      (0.05898 to 0.05909)

      		 ↑

  3. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A011797

      Using a dial indicator, measure the thrust clearance of the crankshaft while moving a screwdriver back and forth between the crankshaft and the crankshaft bearing cap.

      Standard thrust clearance
      0.04 to 0.24 mm (0.0016 to 0.0094 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust washer or crankshaft.

      Thrust washer thickness
      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

  4. INSPECT CYLINDER BLOCK FOR FLATNESS


    1. A0118DT

      Using a precision straightedge and feeler gauge, measure the warpage of the top surface of the cylinder block sub-assembly.

      Maximum warpage
      0.05 mm (0.0020 in.)

  5. INSPECT CYLINDER BORE


    1. A011BSWE01

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

      Standard diameter
      73.000 to 73.013 mm (2.8740 to 2.8745 in.)
      Maximum diameter
      73.13 mm (2.8792 in.)

      Tech Tips

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

  6. INSPECT WITH PIN PISTON SUB-ASSEMBLY


    1. A011AD7E02

      Using a micrometer, measure the piston diameter at right angles to the piston pin center line, and at a position 52 mm (2.05 in.) from the top of the piston head.

      Piston diameter
      72.966 to 72.980 mm (2.8727 to 2.8732 in.)

      Tech Tips

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

    2. A0119QY

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

      Standard Piston Pin Hole Diameter
      Item

      Specified Condition

      mm (in.)
      Mark A

      27.019 to 27.023

      (1.06374 to 1.06390)
      Mark B

      27.023 to 27.027

      (1.06390 to 1.06405)
      Mark C

      27.027 to 27.031

      (1.06405 to 1.06421)
    3. A011BBQ

      Using a micrometer, measure the external diameter of the piston pin.

      Standard Piston Pin Diameter
      Item

      Specified Condition

      mm (in.)
      Mark A

      27.008 to 27.012

      (1.06331 to 1.06346)
      Mark B

      27.012 to 27.016

      (1.06346 to 1.06362)
      Mark C

      27.016 to 27.020

      (1.06362 to 1.06378)

      Note

      Do not change the combinations of the pistons and piston pins so that they can be returned to their original locations when reassembling.

  7. INSPECT PISTON CLEARANCE


    1. Subtract the piston pin hole diameter measurement from the cylinder bore minimum diameter measurement to calculate the piston clearance.

      Standard oil clearance
      0.050 to 0.077 mm (0.0020 to 0.0030 in.)
      Maximum oil clearance
      0.08 mm (0.0032 in.)

      If the piston clearance is greater than the maximum, replace the piston or cylinder block sub-assembly.

  8. INSPECT RING GROOVE CLEARANCE


    1. A0117YW

      Using a feeler gauge, measure the clearance between the piston ring and ring groove all around the piston.

      Standard Ring Groove Clearance
      Ring

      Standard

      mm (in.)
      No. 1

      0.110 to 0.150

      (0.0043 to 0.0059)
      No. 2

      0.075 to 0.110

      (0.0030 to 0.0043)
      Oil

      0.030 to 0.070

      (0.0012 to 0.0028)

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

  9. INSPECT PISTON RING END GAP


    1. A011BJME03

      Using the piston, push the piston ring until it is 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.

    2. A0117EA

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Ring

      Standard

      mm (in.)

      Maximum

      mm (in.)
      No. 1

      0.17 to 0.27

      (0.0067 to 0.0106)

      0.91

      (0.0358)
      No. 2

      0.41 to 0.54

      (0.0161 to 0.0213)

      1.06

      (0.0417)
      Oil

      0.20 to 0.40

      (0.0079 to 0.0158)

      0.82

      (0.0323)

      If the end gap is greater than the maximum, replace the piston ring and oil ring.

  10. INSPECT CONNECTING ROD SUB-ASSEMBLY


    1. A011B86

      Using a caliper gauge, measure the internal diameter of the connecting rod sub-assembly.

      Standard Connecting Rod Internal Diameter
      Item

      Specified Condition

      mm (in.)
      Mark A

      27.022 to 27.026

      (1.06386 to 1.06401)
      Mark B

      27.026 to 27.030

      (1.06401 to 1.06417)
      Mark C

      27.030 to 27.034

      (1.06417 to 1.06433)

      If the diameter is greater than the maximum, replace the connecting rod sub-assembly.

    2. A011AXZE05

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


      1. Check the misalignment.

        Maximum misalignment
        0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

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

      2. A0117LME05

        Check the twist.

        Maximum twist
        0.05 mm (0.002 in.) per 100 mm (3.94 in.)

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

  11. INSPECT CONNECTING ROD BOLT


    1. A01194A

      Using a vernier caliper, measure the diameter at the position illustrated.

      Standard diameter
      6.6 to 6.7 mm (0.260 to 0.264 in.)
      Minimum diameter
      6.4 mm (0.252 in.)

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

  12. INSPECT CRANKSHAFT


    1. A011758

      Inspect the circle runout.


      1. Using a dial indicator and V-blocks, measure the circle runout of the crankshaft.

        Maximum circle runout
        0.015 mm (0.0006 in.)

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

    2. A0117EP

      Inspect the diameter.


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

        Diameter
        45.988 to 46.000 mm (1.8105 to 1.8110 in.)

      2. Calculate the taper and out-of-roundness of the main journal.

        Maximum taper and out-of-round
        0.02 mm (0.0008 in.)

        If the taper and out-of-roundness are greater than the maximum, replace the crankshaft.

      3. A011B8Q

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

        Diameter
        39.992 to 40.000 mm (1.5745 to 1.5748 in.)

      4. Calculate the taper and out-of-roundness of the crank pin.

        Maximum taper and out-of-round
        0.02 mm (0.0008 in.)

        If the taper and out-of-roundness are greater than the maximum, replace the crankshaft.

  13. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A011AZJE01
      Text in Illustration
      *a Measurement Area

      Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

      Standard diameter
      10.8 to 11.0 mm (0.425 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)

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

  14. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Clean the main journal and crankshaft bearing.

      A011B7ME03
      Text in Illustration
      *1 Oil Groove - -

    2. Install the upper bearing with the oil groove onto the cylinder block sub-assembly, the lower bearing onto the bearing cap.

      Note

      Do not apply engine oil to the contact surface of the cylinder block sub-assembly or the back side of the crankshaft bearing.

      Tech Tips

      Mass production parts do not have identification marks. If reusing a mass production part, measure the clearance of both sides so that the bearing is in the center of the bearing cap.

      Specified clearance
      A - B = within 0.8 mm (0.032 in.)

    3. Install the crankshaft onto the cylinder block sub-assembly.

    4. A0118ZFE02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across the crankshaft journal.

    5. A0119L5E01

      Examine the front marks and imprinted numbers and check that the sequence is as shown in the illustration. Then, install the bearing caps onto the cylinder block sub-assembly.

    6. A011BVBE02

      Apply a light coat of engine oil to the threads and contact surface of the bolt.

    7. Using several steps, temporarily tighten the bolts in the sequence shown in the illustration, and tighten them to the specified torque (step "g").

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
    8. A011BV6E11
      Text in Illustration
      *1 Paint Mark

      Mark the front of the crankshaft bearing cap bolts with paint.

    9. Retighten the bearing cap bolts by 90° in the same sequence as step "g".

    10. Check that each paint mark is now at a 90° angle from the front.

      Note

      Do not turn the crankshaft when measuring.

    11. A011ALL

      Remove the bearing cap, and then measure the Plastigage at its widest point.

      Standard oil clearance
      0.010 to 0.023 mm (0.0004 to 0.0009 in.)
      Maximum oil clearance
      0.07 mm (0.0028 in.)

      Note

      Completely remove the Plastigage.

    12. If the clearance is greater than the maximum, select and install a replacement crankshaft bearing.

      Tech Tips


      • To select the correct bearing size, calculate the bearing number by adding together the numbers imprinted on the cylinder block sub-assembly and crank journal.

        A0119DUE02
        Text in Illustration
        *1 Cylinder Block Number *2 Crank Journal Number
        *3 Bearing Number - -

      • Example:

        Imprinted number on the cylinder block is 3.

        Imprinted number on the crank journal is 4.

        3 + 4 = 7

        Select a bearing with the bearing number 3.

        Number

        Cylinder Block Main Journal Bore Diameter

        mm (in.)

        Crank Main Journal Diameter

        mm (in.)
        0

        50.000 to 50.002

        (1.96850 to 1.96858)

        45.999 to 46.000

        (1.81098 to 1.81102)
        1

        50.003 to 50.004

        (1.96862 to 1.96866)

        45.997 to 45.998

        (1.81091 to 1.81094)
        2

        50.005 to 50.006

        (1.96870 to 1.96874)

        45.995 to 45.996

        (1.81083 to 1.81087)
        3

        50.007 to 50.009

        (1.96878 to 1.96886)

        45.993 to 45.994

        (1.81075 to 1.81079)
        4

        50.010 to 50.011

        (1.96890 to 1.96894)

        45.991 to 45.992

        (1.81067 to 1.81071)
        5

        50.012 to 50.013

        (1.96898 to 1.96902)

        45.998 to 45.990

        (1.81094 to 1.81063)
        6

        50.014 to 50.015

        (1.96906 to 1.96909)

        		 -

        Cylinder Block

        Number + Crank

        Journal Number

        		 Bearing Number

        Center Bearing Thickness

        mm (in.)

        Oil Clearance

        mm (in.)
        0 to 2 1

        1.992 to 1.995

        (0.07843 to 0.07854)

        0.010 to 0.023

        (0.00039 to 0.00091)
        3 to 5 2

        1.996 to 1.998

        (0.07858 to 0.07866)

        		 ↑
        6 to 8 3

        1.999 to 2.001

        (0.07870 to 0.07878)

        		 ↑
        9 to 11 4

        2.002 to 2.004

        (0.07882 to 0.07890)

        		 ↑