CYLINDER BLOCK > INSPECTION

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1. INSPECT CONNECTING ROD THRUST CLEARANCE


    A068077

  1. 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


    A200010E01

  1. Confirm that the matchmarks of the connecting rod sub-assembly and connecting rod cap are aligned.
    Text in Illustration 
    *1
    		Matchmark



    A198448E01

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

    SST
    09205-16011  



    A198461E01

  1. Clean the bearing and connecting rod sub-assembly end crank pin.
    Text in Illustration 
    *1
    		Plastigage

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

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



    A198462E01

  1. 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.
    Text in Illustration 
    *1
    		Front Mark

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



    A198448E01

  1. 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 }



    A050671E11

  1. Mark the front of the connecting cap bolts with paint.
    Text in Illustration 
    *1
    		Paint Mark

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

    NOTICE:
    Do not turn the crankshaft when measuring.



    A198463

  1. 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.)

    NOTICE:
    Completely remove the Plastigage.



    A198464E02

  1. If the clearance is greater than the maximum, select and install a replacement connecting rod bearing.
    Text in Illustration 
    *1
    		Front Mark
    *2
    		Number Mark

    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


    A198465

  1. 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


    A198466

  1. 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


    A198476E01

  1. 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.)

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



6. INSPECT WITH PIN PISTON SUB-ASSEMBLY


    A125812E02

  1. 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.)

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



    A128837

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

    Piston pin hole diameter:
    27.019 to 27.031 mm (1.0637 to 1.0642 in.) at 20°C (68°F)



    EM00227

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

    Piston pin diameter:
    27.008 to 27.020 mm (1.0633 to 1.0638 in.)

    NOTICE:
    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


    A111332

  1. 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


    A111333E03

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



    A101491

  1. 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


    A111344

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

    Connecting rod internal diameter:
    27.022 to 27.034 mm (1.0639 to 1.0643 in.)

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



    A054727E05

  1. 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. A054728E05

    2. 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


    A015065

  1. 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


    A069780

  1. 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.



    A069799

  1. 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. A069798

    3. 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


    A015065

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

    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.


    A198454E03


    Text in Illustration 
    *1
    		Oil Groove
    		-
    		-

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

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

    HINT:
    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.)

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



    A198467E02

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



    A198455E01

  1. 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.



    A198450E02

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

  1. 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 }



    A050671E11

  1. Mark the front of the crankshaft bearing cap bolts with paint.
    Text in Illustration 
    *1
    		Paint Mark

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

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

    NOTICE:
    Do not turn the crankshaft when measuring.



    A198468

  1. 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.)

    NOTICE:
    Completely remove the Plastigage.

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

    HINT:

    1. 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.


      A198469E02


      Text in Illustration 
      *1
      		Cylinder Block Number
      		*2
      		Crank Journal Number
      *3
      		Bearing Number
      		-
      		-
    2. 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)
      		↑