CYLINDER BLOCK INSPECTION

PROCEDURE


  1. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A01OBATC04
      *a Straightedge
      *b Feeler Gauge

      Using a precision straightedge and feeler gauge, check the surface that contacts the cylinder head gasket for warpage.

      Maximum Warpage
      0.05 mm (0.00197 in.)

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

  2. INSPECT CYLINDER BORE


    1. A01ODKJC03
      *a Axial Direction
      *b Thrust Direction
      *c Center
      *d 10 mm (0.394 in.)
      B008GAS Front of Engine

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

      Reference Diameter (New Parts)
      90.000 to 90.013 mm (3.54330 to 3.54381 in.)
      Maximum Diameter
      90.13 mm (3.54842 in.)

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

  3. INSPECT PISTON


    1. A01O9Z7C02
      *a Gasket Scraper

      Using a gasket scraper, remove any carbon from the piston top.

    2. A01OA5E

      Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

    3. A01OBZ0

      Using a brush and solvent, thoroughly clean the piston.

      Note

      Do not use a wire brush.

    4. A01O9N0C02
      *a 10.5 mm (0.413 in.)

      Using a micrometer, measure the piston diameter at a position that is 10.5 mm (0.413 in.) from the bottom of the piston (refer to the illustration).

      Reference Piston Diameter (New Parts)
      89.986 to 89.996 mm (3.54275 to 3.54314 in.)

  4. INSPECT PISTON OIL CLEARANCE


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

      Reference Oil Clearance (New Parts)
      0.004 to 0.027 mm (0.000157 to 0.00106 in.)
      Maximum Oil Clearance
      0.10 mm (0.00394 in.)

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

  5. INSPECT RING GROOVE CLEARANCE


    1. A01O97QC03
      *a Feeler Gauge

      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.

  6. INSPECT PISTON RING END GAP


    1. A01O9ZKC03
      *a 120 mm (4.72 in.)

      Using a piston, push in the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block sub-assembly.

    2. A01O9PH

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 compression ring 0.22 to 0.27 mm (0.00866 to 0.0106 in.)
      No. 2 compression ring 0.50 to 0.55 mm (0.0197 to 0.0217 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 0.87 mm (0.0343 in.)
      No. 2 compression ring 1.15 mm (0.0453 in.)
      Oil ring 0.95 mm (0.0374 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.

  7. INSPECT PISTON PIN OIL CLEARANCE


    1. Check each mark on the piston, piston pin and connecting rod.

      A01O9M7C02
      *a Front Mark *b Piston Pin Hole Inside Diameter Mark
      *c Connecting Rod Small End Bush Inside Diameter Mark - -
    2. A01OBRO

      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. A01ODDAC05
      *a 5 mm (0.197 in.)
      *b 28 mm (1.10 in.)

      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.)

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

    4. A01ODJ6

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

      Standard Connecting Rod Small End 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.)

      If the diameter is not as specified, replace the connecting rod sub-assembly.

    5. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

      Standard Oil Clearance
      0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
      Maximum Oil Clearance
      0.013 mm (0.000512 in.)

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

    6. 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
      0.017 mm (0.000669 in.)

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

  8. INSPECT CONNECTING ROD SUB-ASSEMBLY


    1. A01OD0L

      Using a connecting 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. A01OCZD

        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.

  9. INSPECT CRANKSHAFT


    1. A01OBVI

      Inspect for runout.


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

        Maximum Runout
        0.03 mm (0.00118 in.)

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

    2. Inspect the main journals.


      1. A01OAKA

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

        Standard Main Journal Diameter
        54.988 to 55.000 mm (2.16 to 2.17 in.)

        If the diameter is not as specified, check the crankshaft 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
        0.003 mm (0.000118 in.)

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

    3. Inspect the crank pins.


      1. A01OC65

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

        Standard Crank Pin Diameter
        51.492 to 51.500 mm (2.02724 to 2.02756 in.)

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

      2. Inspect 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 or out-of-round is more than the maximum, replace the crankshaft.

  10. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Clean each main journal and crankshaft bearing.

    2. Install the crankshaft bearings.

      Click here

      Note

      Do not apply engine oil to the crankshaft bearings.

    3. Install the upper crankshaft thrust washers.

      Click here

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

    5. A01ODA0C05
      *a Plastigage

      Lay a strip of Plastigage across each journal.

    6. Install the crankshaft bearing caps.

      Click here

      Note

      Do not turn the crankshaft.

    7. Remove the crankshaft bearing caps.

      Click here

    8. A01O9XMC05
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.017 to 0.040 mm (0.000669 to 0.00157 in.)
      Maximum Oil Clearance
      0.05 mm (0.00197 in.)

      Note

      Remove the Plastigage completely after the measurement.

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


      • EXAMPLE

        Cylinder block sub-assembly number mark (A) "3" + Crankshaft number mark (B) "4" = Total "7"

        Select the crankshaft bearing diameter marked "3".

        Crankshaft Bearing Chart
        (A) + (B) Use Crankshaft Bearing
        0 to 2 1
        3 to 5 2
        6 to 8 3
        9 to 11 4
        Standard Cylinder Block Journal Inside Diameter (A)
        Item Specified Condition
        Mark 0

        59.000 to 59.002 mm

        (2.32283 to 2.32291 in.)
        Mark 1

        59.003 to 59.004 mm

        (2.32295 to 2.32299 in.)
        Mark 2

        59.005 to 59.006 mm

        (2.32303 to 2.32307 in.)
        Mark 3

        59.007 to 59.009 mm

        (2.32311 to 2.32318 in.)
        Mark 4

        59.010 to 59.011 mm

        (2.32322 to 2.32326 in.)
        Mark 5

        59.012 to 59.013 mm

        (2.32330 to 2.32334 in.)
        Mark 6

        59.014 to 59.016 mm

        (2.32338 to 2.32346 in.)
        Standard Crankshaft Main Journal Diameter (B)
        Item Specified Condition
        Mark 0

        54.999 to 55.000 mm

        (2.16531 to 2.16535 in.)
        Mark 1

        54.997 to 54.998 mm

        (2.16523 to 2.16527 in.)
        Mark 2

        54.995 to 54.996 mm

        (2.16515 to 2.16519 in.)
        Mark 3

        54.993 to 54.994 mm

        (2.16507 to 2.16511 in.)
        Mark 4

        54.991 to 54.992 mm

        (2.16500 to 2.16504 in.)
        Mark 5

        54.988 to 54.990 mm

        (2.16488 to 2.16496 in.)
        Standard Crankshaft Bearing Center Wall Thickness
        Item Specified Condition
        (Silver) (Black)
        Mark 1

        1.991 to 1.994 mm

        (0.07839 to 0.07850 in.)

        1.992 to 1.995 mm

        (0.07843 to 0.07854 in.)
        Mark 2

        1.995 to 1.997 mm

        (0.07854 to 0.07862 in.)

        1.996 to 1.998 mm

        (0.07858 to 0.07866 in.)
        Mark 3

        1.998 to 2.000 mm

        (0.07866 to 0.07874 in.)

        1.999 to 2.001 mm

        (0.07870 to 0.07878 in.)
        Mark 4

        2.001 to 2.003 mm

        (0.07878 to 0.07886 in.)

        2.002 to 2.004 mm

        (0.07882 to 0.07890 in.)

    9. Perform the inspection for each journal.

  11. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A01O9ARC12
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the measurement point 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.)
      Measurement Point (Distance from the Seat)
      58.5 mm (2.30 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.

  12. INSPECT CONNECTING ROD BOLT


    1. A01OAONC20
      *a Measurement Area

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

      Standard Diameter
      8.5 to 8.6 mm (0.335 to 0.339 in.)
      Minimum Diameter
      8.3 mm (0.327 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.

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

  13. INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01OBLSC01
      *a Pin

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

      If the check valve is stuck, replace the No. 2 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. 2 oil nozzle sub-assembly.

    3. A01OAM9N09

      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. 2 oil nozzle sub-assembly.

    4. A01O9KTC05
      *a Pin

      Push the check valve with a pin while covering (A), and blow air into (B). Check that air passes through (C).

      Tech Tips

      Perform the check again while covering (B), pushing the check valve with a pin and blowing air into (A).

      If air does not pass through (C), clean or replace the No. 2 oil nozzle sub-assembly.