ENGINE UNIT INSPECTION


  1. INSPECT BACKLASH OF OIL PUMP GEAR TO CRANKSHAFT TIMING GEAR


    1. A01E1TCE01

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.20 mm (0.0079 in.)

      If the gear backlash is greater than the maximum, replace the gears as a set.

  2. INSPECT NO. 1 IDLE GEAR THRUST CLEARANCE


    1. A01DZLNE01

      Using a dial indicator, measure the thrust clearance.

      Standard thrust clearance
      0.06 to 0.11 mm (0.0024 to 0.0043 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust plate. If necessary, replace the idle gear and/or idle gear shaft.

  3. INSPECT BACKLASH OF CRANKSHAFT TIMING GEAR TO NO. 1 IDLE GEAR

    A01DWATE01

    1. Install the idle gear.

    2. Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.20 mm (0.0079 in.)

      If the gear backlash is greater than the maximum, replace the gears as a set.

    3. Remove the idle gear.

  4. INSPECT BACKLASH OF SUPPLY PUMP GEAR TO NO. 1 GEAR

    A01DZIFE01

    1. Install the supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Using SST, install the supply pump gear with the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 652 kgf*cm, 47 ft.*lbf }

    3. Install the idle gear without the sub-gears.

    4. A01E0T0E01

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.20 mm (0.0079 in.)

      If the gear backlash is greater than the maximum, replace the gears as a set.

    5. Using SST, remove the nut and supply pump gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    6. Remove the 2 nuts and supply pump.

  5. INSPECT NO. 1 IDLE GEAR OIL CLEARANCE


    1. A01E1WGE01

      Using a cylinder gauge, measure the inside diameter of the idle gear.

      Standard idle gear inside diameter
      44.000 to 44.025 mm (1.7323 to 1.7333 in.)
    2. A01DWX6E01

      Using a micrometer, measure the diameter of the idle gear shaft.

      Standard idle gear shaft diameter
      43.955 to 43.990 mm (1.7305 to 1.7319 in.)

    3. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.

      Standard oil clearance
      0.010 to 0.070 mm (0.0004 to 0.0028 in.)
      Maximum oil clearance
      0.20 mm (0.0079 in.)

      If the clearance is greater than the maximum, replace the gear and shaft.

  6. INSPECT CYLINDER HEAD SET BOLT

    A01DW6BE01

    1. Using a vernier caliper, measure the minimum outside diameter of the compressed thread at the measuring point A.

      Standard outside diameter
      11.8 to 12.0 mm (0.465 to 0.472 in.)
      Minimum outside diameter
      11.6 mm (0.457 in.)

      If the outside diameter is less than the minimum, replace the bolt.

  7. INSPECT INJECTION GEAR


    1. Check that the bearing is not rough or worn.

      If necessary, replace the injection gear.

  8. INSPECT CYLINDER BLOCK OIL ORIFICE


    1. Check the oil orifice for damage or clogging.

      If necessary, replace the oil orifice.

  9. INSPECT CONNECTING ROD THRUST CLEARANCE

    A01DX8YE01

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

      Standard thrust clearance
      0.100 to 0.300 mm (0.0039 to 0.0118 in.)
      Maximum thrust clearance
      0.40 mm (0.0157 in.)

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

  10. INSPECT CONNECTING ROD OIL CLEARANCE


    1. Clean the crank pin and bearing.

    2. Check the crank pin and bearing for pitting and scratches.

      If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

    3. A01DWM9E03
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across the crank pin.

    4. A01E0Y8E07
      Text in Illustration
      *1 Matchmark

      Install the connecting rod cap with the 2 bolts.

      Note

      Do not turn the crankshaft.

    5. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

    6. Remove the 2 bolts, connecting rod cap and lower bearing.

    7. A01E01ZE03
      Text in Illustration
      *1 Plastigage
      A01E0XFE03
      Text in Illustration
      *1 Mark 1, 2 or 3
      *2 Mark 2, 3 or 4
      *3 No. 1
      *4 No. 2
      *5 No. 3
      *6 No. 4

      Measure the Plastigage at its widest point.

      Standard oil clearance
      STD 0.036 to 0.054 mm (0.0014 to 0.0021 in.)
      U/S 0.25, U/S 0.50 0.037 to 0.077 mm (0.0015 to 0.0030 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

      If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

      Tech Tips

      If using a standard 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 crankshaft and connecting rod, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

      Item Number Mark
      Connecting rod cap 1 2 3
      Crankshaft 1 2 3 1 2 3 1 2 3
      Use bearing 2 3 4 3 4 5 4 5 6

      EXAMPLE:

      Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")

      Reference
      Standard connecting rod big end inside diameter
      Mark Diameter
      1 62.014 to 62.020 mm (2.4415 to 2.4417 in.)
      2 62.020 to 62.026 mm (2.4417 to 2.4420 in.)
      3 62.026 to 62.032 mm (2.4420 to 2.4422 in.)
      Standard crankshaft pin diameter
      Mark Diameter
      1 58.994 to 59.000 mm (2.3226 to 2.3228 in.)
      2 58.988 to 58.994 mm (2.3224 to 2.3226 in.)
      3 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
      Standard sized bearing center wall thickness
      Mark Diameter
      2 1.486 to 1.489 mm (0.0585 to 0.0586 in.)
      3 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
      4 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
      5 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
      6 1.498 to 1.501 mm (0.0590 to 0.0591 in.)

    8. Completely remove the Plastigage.

  11. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01DWAFE01

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

      Standard thrust clearance
      0.040 to 0.240 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 washers as a set.

      Standard thrust washer thickness
      STD O/S 0.125 O/S 0.250
      2.430 to 2.480 mm (0.0957 to 0.0976 in.) 2.555 to 2.605 mm (0.1006 to 0.1026 in.) 2.680 to 2.730 mm (0.1055 to 0.1074 in.)

  12. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Clean each main journal and bearing.

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

      If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

    3. Place the crankshaft on the cylinder block.

    4. A01DX71E02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across each journal.

    5. A01DVTVE07
      Maximum clearance
      0.10 mm (0.0039 in.)
      Text in Illustration
      *1 Plastigage

      Install the 5 crankshaft bearing caps with the 10 bolts.

      Note

      Do not turn the crankshaft.

    6. Remove the 10 bolts and 5 crankshaft bearing caps.

    7. A01E18OE02
      Text in Illustration
      *1 Plastigage
      A01DWJBE03
      Text in Illustration
      *1 Mark 2, 3, 4, 5 or 6
      *2 No. 1
      *3 No. 2
      *4 No. 3
      *5 No. 4
      *6 No. 5
      *a Front

      Measure the Plastigage at its widest point.

      Standard oil clearance
      STD O/S 0.25, O/S 0.50
      0.030 to 0.048 mm (0.0012 to 0.0019 in.) 0.037 to 0.077 mm (0.0015 to 0.0030 in.)
      Maximum clearance
      0.10 mm (0.0039 in.)
      Text in Illustration
      *1 Plastigage

      If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

      Tech Tips

      If replacing the cylinder block sub-assembly, the bearing standard oil clearance will be within standard value.

      Standard oil clearance
      0.030 to 0.048 mm (0.0012 to 0.0019 in.)

      Tech Tips

      If using a standard bearing, replace it with one having 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 selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

      Item Number Mark
      Cylinder block 1 2 3
      Crankshaft 1 2 3 1 2 3 1 2 3
      Use bearing 2 3 4 3 4 5 4 5 6

      Tech Tips

      EXAMPLE: Cylinder block "2" + crankshaft "1"

      = Total number 3 (Use bearing "3")

      Reference
      Standard cylinder block main journal bore diameter
      Mark Diameter
      1 75.000 to 75.006 mm (2.9528 to 2.9530 in.)
      2 75.006 to 75.012 mm (2.9530 to 2.9532 in.)
      3 75.012 to 75. 018 mm (2.9532 to 2.9535 in.)
      Standard crankshaft journal diameter
      Mark Diameter
      1 69.994 to 70.000 mm (2.7557 to 2.7559 in.)
      2 69.988 to 69.994 mm (2.7554 to 2.7557 in.)
      3 69.982 to 69.988 mm (2.7552 to 2.7554 in.)
      Standard sized bearing center wall thickness
      Mark Diameter
      2 2.482 to 2.485 mm (0.0977 to 0.0978 in.)
      3 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
      4 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      5 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      6 2.494 to 2.497 mm (0.0982 to 0.0983 in.)

    8. Completely remove the Plastigage.

  13. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A01DYS7E05
      Text in Illustration
      *1 Ball
      A01E2TX Push

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

      If stuck, replace the check valve.

  14. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Check the oil nozzles for damage or clogging.

      If necessary, replace the oil nozzle.

  15. CLEAN CYLINDER BLOCK SUB-ASSEMBLY


    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.

  16. INSPECT CYLINDER BLOCK SUB-ASSEMBLY


    1. Inspect for flatness.


      1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head cap for warpage.

        Maximum warpage
        0.10 mm (0.0039 in.)

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

    2. Visually check the cylinder for vertical scratches.

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

    3. Inspect the cylinder bore diameter.


      1. A01E2TLE04
        Text in Illustration
        *1 Axial Direction
        *2 Thrust Direction
        *3 Center
        A01E2TX Front

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

        Standard diameter
        Mark 1 Mark 2 Mark 3
        92.000 to 92.010 mm (3.6220 to 3.6224 in.) 92.010 to 92.020 mm (3.6224 to 3.6228 in.) 92.020 to 92.030 mm (3.6228 to 3.6232 in.)
        Maximum diameter
        STD O/S 0.50
        92.23 mm (3.6311 in.) 92.73 mm (3.6508 in.)

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

    4. A01E0ILE06
      Text in Illustration
      *1 Ridge Reamer

      Remove the cylinder ridge.

      If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

  17. CLEAN PISTON


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

    2. Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  18. INSPECT PISTON

    Tech Tips

    When replacing the piston sub-assembly (w/ pin) with a supply part, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.


    1. Inspect the piston oil clearance.

      Tech Tips

      There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top.


      1. A01E02SE01
        Text in Illustration
        *A for Waste Gate Type Turbocharger
        *B for Variable Nozzle Vane Turbocharger
        *1 Size Mark
        *2 Piston Pin Hole Inside Diameter Mark
        *3 Front Mark (Arrow)
        *4 Distance

        Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston head.

        Standard distance
        65.0 mm (2.56 in.)
        Standard piston diameter
        STD STD STD STD
        Mark 1 Mark 2 Mark 3 O/S 0.50
        91.92 to 91.93 mm (3.6189 to 3.6193 in.) 91.93 to 91.94 mm (3.6193 to 3.6197 in.) 91.94 to 91.95 mm (3.6197 to 3.6201 in.) 92.42 to 92.45 mm (3.6386 to 3.6398 in.)

      2. Measure the cylinder bore diameter in the thrust directions (see "INSPECT CYLINDER BLOCK SUB-ASSEMBLY: Inspect the cylinder bore diameter" procedures).

      3. A01DUY3E01
        Text in Illustration
        *A for Waste Gate Type Turbocharger
        *B for Variable Nozzle Vane Turbocharger
        *1 No. 1
        *2 No. 2
        *3 No. 3
        *4 No. 4
        *5 Mark 1, 2 or 3
        *6 Size Mark

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

        Standard oil clearance
        0.070 to 0.090 mm (0.0028 to 0.0035 in.)
        Maximum oil clearance
        0.16 mm (0.0063 in.)

        If the oil clearance is greater than the maximum, replace all 4 pistons and rebore all 4 cylinders.

        If necessary, replace the cylinder block.

        Tech Tips

        Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.

    2. A01E2G0E01

      Using a micrometer, measure the piston pin diameter.

      Standard piston pin diameter
      A B C
      33.996 to 34.000 mm (1.3384 to 1.3385 in.) 34.000 to 34.004 mm (1.3385 to 1.3387 in.) 34.004 to 34.008 mm (1.3387 to 1.3388 in.)
    3. A01E054

      Inspect the piston pin fit.


      1. At 80°C (176°F), check that the piston pin can be pushed into the piston pin hole with your thumb.

        If the pin can be installed at a lower temperature, replace the piston and pin as a set.

  19. INSPECT PISTON RING SET


    1. Inspect the piston ring groove clearance.


      1. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

        Standard groove clearance
        No. 1 No. 2 Oil
        0.060 to 0.100 mm (0.0024 to 0.0039 in.) 0.050 to 0.095 mm (0.0020 to 0.0037 in.) 0.030 to 0.075 mm (0.0012 to 0.0027 in.)
        Maximum groove clearance
        0.20 mm (0.0079 in.)

        If the clearance is greater than the maximum, replace the piston.

    2. Inspect the 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 and 120 mm (4.72 in.) from the top of the cylinder block.

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

        Standard end gap
        No. 1 No. 2 Oil
        0.270 to 0.390 mm (0.0106 to 0.0154 in.) 0.470 to 0.570 mm (0.0185 to 0.0224 in.) 0.200 to 0.400 mm (0.0079 to 0.0157 in.)
        Maximum end gap
        No. 1 No. 2 Oil
        1.21 mm (0.0476 in.) 1.44 mm (0.0567 in.) 1.22 mm (0.0480 in.)

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

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

  20. INSPECT CONNECTING ROD SUB-ASSEMBLY


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


      1. A01E0A5

        Check for bend.

        Maximum bend
        0.03 mm (0.0012 in.) per 100 mm (3.94 in.)

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

      2. A01DV2X

        Check for rod is twisted.

        Maximum twist
        0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

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

  21. INSPECT PISTON PIN OIL CLEARANCE


    1. Inspect the piston pin oil clearance.


      1. A01DVQWE02
        Text in Illustration
        *1 Connecting Rod Bush Inside Diameter Mark A, B or C
        *2 Front Mark

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

        Standard bush inside diameter
        Size Mark Diameter
        A 34.012 to 34.016 mm (1.3390 to 1.3392 in.)
        B 34.016 to 34.020 mm (1.3392 to 1.3394 in.)
        C 34.020 to 34.024 mm (1.3394 to 1.3395 in.)

      2. Subtract the piston pin diameter measurement from the bush inside diameter measurement.

        Standard oil clearance
        0.012 to 0.024 mm (0.0005 to 0.0009 in.)
        Maximum oil clearance
        0.03 mm (0.0012 in.)

        If the oil clearance is greater than the maximum, replace the bush.

        If necessary, replace the piston and piston pin with a new piston and pin set.

  22. INSPECT CONNECTING ROD BOLT


    1. A01DZB1E08
      Text in Illustration
      *1 Tension Portion

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

      Standard diameter
      8.500 to 8.600 mm (0.3346 to 0.3385 in.)
      Minimum diameter
      8.30 mm (0.3268 in.)

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

  23. INSPECT CRANKSHAFT


    1. Inspect for 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 (0.0012 in.)

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

    2. A01DW7IE01

      Inspect the main journals and crank pins.


      1. Using a micrometer, measure the diameter of each main journal and crank pin.

        Standard main journal diameter
        STD U/S 0.25 U/S 0.50
        69.982 to 70.000 mm (2.7552 to 2.7559 in.) 69.745 to 69.755 mm (2.7459 to 2.7463 in.) 69.495 to 69.505 mm (2.7360 to 2.7364 in.)
        Standard crankshaft pin diameter
        STD U/S 0.25 U/S 0.50
        58.982 to 59.000 mm (2.3221 to 2.3228 in.) 58.745 to 58.755 mm (2.3128 to 2.3132 in.) 58.495 to 58.505 mm (2.3029 to 2.3033 in.)

        If the diameter is not as specified, check the oil clearance (see "INSPECT CONNECTING ROD OIL CLEARANCE" and "INSPECT CRANKSHAFT THRUST CLEARANCE" procedures). If necessary, grind or replace the crankshaft.

      2. Check each main journal and crank pin for taper and out-of-round as shown.

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

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

    3. If necessary, grind and hone the main journals and/or crank pins.


      1. Grind and hone the main journals and/or crank pins to the finished undersized diameter (see procedures above).

      2. Install new main journal and/or crankshaft pin undersized bearing.

  24. INSPECT CRANKSHAFT BEARING CAP BOLT


    1. A01E09HE03
      Text in Illustration
      *1 Measuring Point
      *2 Elongated Thread

      Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.

      Standard diameter
      13.500 to 14.000 mm (0.5315 to 0.5512 in.)
      Minimum diameter
      12.60 mm (0.4961 in.)

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