CYLINDER BLOCK > INSPECTION

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1. CLEAN PISTON


A104706

  1. Using an old piston ring or similar device, remove all carbon on each piston.

    CAUTION:
    Wear protective goggles while servicing.

    NOTICE:
    Do not damage the piston while servicing.

  1. Clean all the carbon off each part using solvent.



2. INSPECT CYLINDER BLOCK


A203210

  1. Using a straightedge and feeler gauge, measure the warpage of the contact surface indicated in the illustration.

    Maximum warpage:
    0.05 mm (0.002 in.)

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



3. INSPECT CYLINDER BORE


A232563E01

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

    Standard diameter:
    71.000 to 71.013 mm (2.79527 to 2.79578 in.)

    Maximum diameter:
    71.133 mm (2.80051 in.)

    If the cylinder bore diameter at any 1 position is greater than the maximum, replace the cylinder block.



    A104709E01

  1. Calculate the elliptic degree and tapered amount from the measured values.

    Maximum elliptic degree and tapered amount:
    0.02 mm (0.0008 in.)

    HINT:
    1. Elliptic degree: A - B or a - b
    2. Tapered amount: A - a or B - b



4. INSPECT PISTON


A229085E01

  1. Measure the outer diameter of the piston in the vertical direction to the pin hole, at the point 12.7 mm (0.500 in.) away from the bottom end of the skit.

    Piston diameter:
    70.945 to 70.963 mm (2.79311 to 2.79381 in.)

    Minimum diameter:
    70.945 mm (2.79311 in.)

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



5. INSPECT PISTON RING GROOVE CLEARANCE


A104711

  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
    		Specification
    No. 1 ring
    		0.02 to 0.07 mm (0.0008 to 0.0028 in.)
    No. 2 ring
    		0.02 to 0.06 mm (0.0008 to 0.0024 in.)
    Oil ring
    		0.020 to 0.065 mm (0.00079 to 0.00256 in.)

    Maximum Ring Groove Clearance:
    Item
    		Specification
    No. 1 ring
    		0.07 mm (0.0028 in.)
    No. 2 ring
    		0.06 mm (0.0024 in.)
    Oil ring
    		0.065 mm (0.00256 in.)

    If the ring groove clearance is greater than the maximum, replace the piston assembly.



6. INSPECT PISTON RING END GAP


A001170E01

  1. Using a piston, push the piston ring a little beyond the bottom of the ring travel, which is 45 mm (1.77 in.) from the top of the cylinder block.



    A106780

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

    Standard End Gap:
    Item
    		Specification
    No. 1 ring
    		0.15 to 0.25 mm (0.0059 to 0.0098 in.)
    No. 2 ring
    		0.40 to 0.60 mm (0.0157 to 0.0236 in.)
    Oil ring
    		0.10 to 0.40 mm (0.0039 to 0.0157 in.)

    Maximum End Gap:
    Item
    		Specification
    No. 1 ring
    		0.25 mm (0.0098 in.)
    No. 2 ring
    		0.60 mm (0.0236 in.)
    Oil ring
    		0.40 mm (0.0158 in.)

    1. If the end gap is greater than the maximum, replace the piston ring.
    2. If the end gap is greater than the maximum, even with a new piston ring, replace the cylinder block.



7. INSPECT PISTON OIL CLEARANCE

  1. Subtract the piston diameter measurement from the cylinder bore diameter measurement to calculate the oil clearance.

    Standard oil clearance:
    0.037 to 0.068 mm (0.00146 to 0.00268 in.)

    Maximum oil clearance:
    0.098 mm (0.00386 in.)

    1. If the clearance is greater than the maximum, replace all of the piston assemblies.
    2. If necessary, replace the cylinder block.

    HINT:
    1. The oil clearance of the piston and cylinder block can be calculated by subtracting the cylinder inner diameter in the thrust direction from the piston outer diameter.
    2. Perform the measurement at the point with the most wear because there is joggling wear on the upper end of the piston ring sliding area.



8. INSPECT CONNECTING ROD SUB-ASSEMBLY


A104716

  1. Using a cylinder gauge, measure the connecting rod sub-assembly big end diameter, as shown in the illustration.

    Standard diameter:
    43.000 to 43.024 mm (1.69291 to 1.63985 in.)

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



9. INSPECT CONNECTING ROD BOLT


A001470

  1. Using a vernier caliper, measure the tension portion.

    Minimum diameter:
    6.4 mm (0.252 in.)

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



10. INSPECT CONNECTING ROD BEARING


A104717

  1. Using a micrometer, measure the thickness of the connecting rod bearing.

    Standard thickness:
    1.492 to 1.501 mm (0.05874 to 0.05909 in.)

    If the thickness is not as specified, replace the connecting rod bearing.



11. INSPECT CONNECTING ROD THRUST CLEARANCE

  1. Install the crankshaft with crankshaft journal bearing onto the cylinder block.

  1. Install the thrust washer upper.

  1. Install the piston with pin into the connecting rod.

  1. Install the piston ring onto the piston.

  1. Install the connecting rod assembly with connecting rod bearing onto the crankshaft.



    A203195

  1. Using a feeler gauge, measure the thrust clearance of the connecting rod.

    Standard thrust clearance:
    0.1 to 0.3 mm (0.004 to 0.012 in.)

    Maximum thrust clearance:
    0.36 mm (0.0138 in.)



12. INSPECT CONNECTING ROD OIL CLEARANCE


A203196

NOTICE:
Do not turn the crankshaft.

  1. Remove the 2 bolts, connecting rod bearing cap and connecting rod bearing.

    NOTICE:
    Arrange the removed parts for each cylinder in order.



    A104747

  1. Clean the connecting rod bearing and crank pin.



    A203197E01

  1. Lay a strip of Plastigage across the crank pin.
    Text in Illustration 
    *1
    		Plastigage

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

  1. Tighten the 2 bolts in several steps to the specified torque.

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }



    A203200

  1. Remove the 2 bolts, the connecting rod bearing cap and the connecting rod bearing.

  1. Measure the Plastigage at its widest point.

    Standard oil clearance:
    0.010 to 0.036 mm (0.00039 to 0.00142 in.)

    Maximum oil clearance:
    0.036 mm (0.00142 in.)

    NOTICE:
    Completely remove the Plastigage after the measurement.

    HINT:
    1. If the oil clearance is greater than the maximum, replace the connecting rod bearing with one with the same mark.
    2. If the oil clearance is still greater than the maximum even after the connecting rod bearing is replaced, replace the crankshaft.
    Item
    		Mark
    		Specification
    Connecting rod bearing cap bore diameter
    		1
    		43.000 to 43.008 mm (1.69291 to 1.69323 in.)
    2
    		43.009 to 43.016 mm (1.69324 to 1.69355 in.)
    3
    		43.017 to 43.024 mm (1.69356 to 1.69385 in.)
    Connecting rod bearing thickness
    		1
    		1.492 to 1.495 mm (0.05874 to 0.05886 in.)
    2
    		1.495 to 1.498 mm (0.05886 to 0.05898 in.)
    3
    		1.498 to 1.501 mm (0.05898 to 0.05909 in.)
    Crankshaft pin outer diameter
    		-
    		39.992 to 40.000 mm (1.57445 to 1.57480 in.)

    HINT:
    The procedures for measuring the connecting rod bearing cap bore diameter and the connecting rod thickness are described in the engine unit inspection section.

  1. Perform the measurement for the other connecting rod oil clearance using the same procedure.



13. INSPECT CRANKSHAFT


A104712

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

    Maximum circle runout:
    0.03 mm (0.0012 in.)

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

    HINT:
    The runout is the half of the value on the indicator when the crankshaft is turned 1 revolution.



    A104713E01

  1. Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.

    Diameter:
    43.988 to 44.000 mm (1.73181 to 1.73228 in.)

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

  1. Check each main journal for elliptic degree and tapered amount as shown.

    Maximum elliptic degree and tapered amount:
    0.03 mm (0.0012 in.)

    If the elliptic degree or tapered amount is greater than the maximum, replace the crankshaft.

    HINT:
    1. Elliptic degree: A - B or a - b
    2. Tapered amount: A - a or B - b



    A104714E01

  1. Using a micrometer, measure the diameter of each crankshaft pin at the points shown in the illustration.

    Diameter:
    39.992 to 40.000 mm (1.57449 to 1.57480 in.)

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

  1. Check each crankshaft pin for elliptic degree and tapered amount as shown.

    Maximum elliptic degree and tapered amount:
    0.03 mm (0.0012 in.)

    If the elliptic degree or tapered amount is greater than the maximum, replace the crankshaft.

    HINT:
    1. Elliptic degree: A - B or a - b
    2. Tapered amount: A - a or B - b



14. INSPECT CRANKSHAFT THRUST CLEARANCE


A203202

  1. Install the crankshaft with crankshaft bearing onto the cylinder block.

  1. Using a feeler gauge, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

    Standard clearance:
    0.02 to 0.04 mm (0.0008 to 0.0016 in.)

    Maximum clearance:
    0.30 mm (0.0118 in.)

    HINT:
    1. If the thrust clearance is greater than the maximum, replace the thrust washer.
    2. If the clearance is still greater than the maximum, replace the crankshaft.



15. INSPECT CRANKSHAFT OIL CLEARANCE


A203203E02

NOTICE:
Do not turn the crankshaft.

  1. Remove the 8 bolts in the order shown in the illustration.

  1. Remove the 4 crankshaft bearing caps.

  1. Clean the main journal and crankshaft bearings.

  1. Check these parts for excessive wear and damage.



    A203205E01

  1. Lay a strip of Plastigage in the axial direction of the crankshaft journal.
    Text in Illustration 
    *1
    		Plastigage



    A203203E03

  1. Tighten the 8 bolts to the specified torque.

    Torque:
    59 N*m{ 602 kgf*cm , 44 ft.*lbf }

    NOTICE:
    Tighten the crankshaft bearing cap bolts in 2 or 3 steps, in the order shown in the illustration.



    A203204

  1. Remove the 2 bolts, then remove the crankshaft bearing cap and crankshaft bearing.



    A203206

  1. Measure the Plastigage at its widest point.

    Standard oil clearance:
    0.006 to 0.024 mm (0.00024 to 0.00094 in.)

    Maximum oil clearance:
    0.024 mm (0.00094 in.)

    NOTICE:
    Completely remove the Plastigage after the measurement.

    HINT:
    1. If the oil clearance is greater than the maximum, replace the crankshaft bearing with one with the same mark.
    2. If the oil clearance is still greater than the maximum even after the crankshaft bearing is replaced, replace the crankshaft.
    3. When replacing a bearing, first check the number on the cylinder block for the bearing's respective journal. Then replace the bearing with one with the same number. Each bearing's standard thickness is indicated by a number 1, 2, 3 or 4 mark on its surface.
    Item
    		Mark
    		Specification
    Cylinder block journal bore diameter
    		1
    		48.000 to 48.006 mm (1.88976 to 1.89000 in.)
    2
    		48.006 to 48.012 mm (1.89000 to 1.89023 in.)
    3
    		48.012 to 48.018 mm (1.89023 to 1.89047 in.)
    Crankshaft journal diameter
    		1
    		43.994 to 44.000 mm (1.73204 to 1.73228 in.)
    2
    		43.988 to 43.994 mm (1.73171 to 1.73204 in.)
    Standard bearing center wall thickness
    		2
    		1.994 to 1.997 mm (0.07850 to 0.07862 in.)
    3
    		1.997 to 2.000 mm (0.07862 to 0.07874 in.)
    4
    		2.000 to 2.003 mm (0.07874 to 0.07886 in.)



16. INSPECT CRANKSHAFT THRUST WASHER UPPER


A104715

  1. Using a micrometer, measure the thrust thickness of the crankshaft thrust washer upper.

    Standard thickness:
    1.94 to 1.99 mm (0.0764 to 0.0783 in.)

    If the thickness is not as specified, replace the crankshaft thrust washer upper.