CYLINDER BLOCK > INSPECTION

for Preparation Click here



1. INSPECT CRANKSHAFT


    A198685

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

    Maximum circle runout:
    0.02 mm (0.000787 in.)

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



    A198686E01

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

    Standard diameter:
    47.988 to 48.000 mm (1.88929 to 1.88976 in.)

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

  1. Check each main journal for taper and distortion as shown in the illustration.

    Maximum taper and distortion:
    0.003 mm (0.000118 in.)

    If the taper and distortion are greater than the maximum, replace the crankshaft.

    Standard Diameter (Reference):
    Mark
    		Specified Condition
    0
    		47.999 to 48.000 mm (1.88972 to 1.88976 in.)
    1
    		47.997 to 47.998 mm (1.88964 to 1.88968 in.)
    2
    		47.995 to 47.996 mm (1.88956 to 1.88960 in.)
    3
    		47.993 to 47.994 mm (1.88948 to 1.88952 in.)
    4
    		47.991 to 47.992 mm (1.88941 to 1.88945 in.)
    5
    		47.988 to 47.990 mm (1.88929 to 1.88937 in.)



    A199398

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

    Standard diameter:
    41.992 to 42.000 mm (1.6532 to 1.6535 in.)

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

  1. Inspect each crank pin for taper and distortion as shown in the illustration.

    Maximum taper and distortion:
    0.003 mm (0.000118 in.)

    If the taper and distortion are greater than the maximum, replace the crankshaft.



2. INSPECT CYLINDER BLOCK FOR WARPAGE


    A198677

  1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.

    Maximum warpage:
    0.05 mm (0.00197 in.)

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



3. INSPECT CYLINDER BORE


    A198678E03

  1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both thrust and axial directions.
    Text in Illustration 
    *a
    		Thrust Direction
    *b
    		Axial Direction
    V100135
    		Front

    Standard diameter:
    72.500 to 72.513 mm (2.8543 to 2.8548 in.)

    Maximum diameter:
    72.63 mm (2.8594 in.)

    If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.



4. INSPECT PISTON


    A198679

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



    A198680

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



    A198681

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

    NOTICE:
    Do not use a wire brush.



    A198682E01

  1. Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 8.8 mm (0.346 in.) from the piston bottom.

    Standard piston diameter:
    72.435 to 72.445 mm (2.8518 to 2.8522 in.)

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



5. INSPECT PISTON OIL CLEARANCE

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

    Standard oil clearance:
    0.055 to 0.078 mm (0.00217 to 0.00307 in.)

    Maximum oil clearance:
    0.108 mm (0.00425 in.)

    If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.



6. INSPECT RING GROOVE CLEARANCE


    A198683

  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
    		Specified Condition
    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
    		0.02 to 0.06 mm (0.0008 to 0.0024 in.)

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



7. INSPECT PISTON RING END GAP


    A198684E01

  1. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 50 mm (1.97 in.) from the top of the cylinder block.



    EM02552E01

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

    Standard End Gap:
    Item
    		Specified Condition
    No. 1 ring
    		0.18 to 0.25 mm (0.00709 to 0.00984 in.)
    No. 2 ring
    		0.30 to 0.45 mm (0.0118 to 0.0177 in.)
    Oil ring
    		0.10 to 0.40 mm (0.00394 to 0.0157 in.)

    Maximum End Gap:
    Item
    		Specified Condition
    No. 1 ring
    		0.45 mm (0.0177 in.)
    No. 2 ring
    		0.65 mm (0.0256 in.)
    Oil ring
    		0.55 mm (0.0217 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, replace the cylinder block.



8. INSPECT CRANKSHAFT THRUST CLEARANCE


    A198687

  1. Install the main bearing cap (Click here).

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

    Standard thrust clearance:
    0.04 to 0.24 mm (0.00157 to 0.00945 in.)

    Maximum thrust clearance:
    0.28 mm (0.0110 in.)

    If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

    HINT:
    The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).



9. INSPECT CONNECTING ROD THRUST CLEARANCE


    A198673

  1. Install the connecting rod cap (Click here).

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

    Standard thrust clearance:
    0.1 to 0.5 mm (0.00394 to 0.0197 in.)

    Maximum thrust clearance:
    0.5 mm (0.0197 in.)

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



10. INSPECT CRANKSHAFT OIL CLEARANCE


    A198688E02

  1. Check the crank journal and bearing for pitting and scratches.

  1. Install the crankshaft bearing (Click here).

  1. Place the crankshaft on the cylinder block.
    Text in Illustration 
    *1
    		Plastigage

  1. Lay a strip of Plastigage across each journal.

  1. Examine the front marks and numbers and install the bearing caps on the cylinder block.

    HINT:
    A number is marked on each main bearing cap to indicate the installation position.

  1. Install the main bearing cap (Click here).

    NOTICE:
    Do not turn the crankshaft.

  1. Remove the main bearing caps (Click here).



    A198689E04

  1. Measure the Plastigage at its widest point.
    Text in Illustration 
    *1
    		Plastigage
    *a
    		Number Marks

    Standard oil clearance:
    0.019 to 0.043 mm (0.000748 to 0.00169 in.)

    Maximum oil clearance:
    0.049 mm (0.00192 in.)

    If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

    NOTICE:
    Remove the Plastigage completely after the measurement.

    HINT:
    1. If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number according to the chart below. There are 4 sizes of standard bearings, marked "2", "3", "4" and "5" accordingly.
    2. EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "4")
    Cylinder block + Crankshaft
    		0 to 2
    		3 to 5
    		6 to 8
    		9 to 11
    Bearing to be used
    		"2"
    		"3"
    		"4"
    		"5"

    Standard Cylinder Block Journal Bore Diameter:
    Mark
    		Specified Condition
    0
    		52.000 to 52.002 mm (2.04724 to 2.04732 in.)
    1
    		52.003 to 52.004 mm (2.04736 to 2.04740 in.)
    2
    		52.005 to 52.006 mm (2.04744 to 2.04748 in.)
    3
    		52.007 to 52.009 mm (2.04752 to 2.04759 in.)
    4
    		52.010 to 52.011 mm (2.04763 to 2.04767 in.)
    5
    		52.012 to 52.013 mm (2.04771 to 2.04775 in.)
    6
    		52.014 to 52.016 mm (2.04779 to 2.04787 in.)

    Standard Crankshaft Journal Diameter:
    Mark
    		Specified Condition
    0
    		47.999 to 48.000 mm (1.88972 to 1.88976 in.)
    1
    		47.997 to 47.998 mm (1.88964 to 1.88968 in.)
    2
    		47.995 to 47.996 mm (1.88956 to 1.88960 in.)
    3
    		47.993 to 47.994 mm (1.88948 to 1.88952 in.)
    4
    		47.991 to 47.992 mm (1.88941 to 1.88945 in.)
    5
    		47.988 to 47.990 mm (1.88929 to 1.88937 in.)

    Standard Bearing Center Wall Thickness:
    Mark
    		Specified Condition
    2
    		1.994 to 1.997 mm (0.07850 to 0.07862 in.)
    3
    		1.998 to 2.000 mm (0.07866 to 0.07874 in.)
    4
    		2.001 to 2.003 mm (0.07878 to 0.07886 in.)
    5
    		2.004 to 2.006 mm (0.07890 to 0.07898 in.)



11. INSPECT CONNECTING ROD OIL CLEARANCE


    A198674E02

  1. Clean the crank pin and bearing.

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

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



    A198666E04

  1. Check that the front mark of the connecting rod cap is facing forward.
    Text in Illustration 
    *a
    		Front Mark

  1. Install the connecting rod cap (Click here).

    NOTICE:
    Do not turn the crankshaft.

  1. Remove the 2 bolts and connecting rod cap (Click here).



    A198676E03

  1. Measure the Plastigage at its widest point.
    Text in Illustration 
    *1
    		Plastigage
    *a
    		Mark

    Standard oil clearance:
    0.020 to 0.052 mm (0.000787 to 0.002047 in.)

    Maximum oil clearance:
    0.055 mm (0.00217 in.)

    If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

    NOTICE:
    Completely remove the Plastigage after the measurement.

    HINT:
    If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by mark 1, 2, or 3 on its surface.

    Standard Connecting Rod Large End Bore Diameter:
    Mark
    		Specified Condition
    Mark 1
    		45.000 to 45.008 mm (1.77165 to 1.77197 in.)
    Mark 2
    		45.009 to 45.016 mm (1.77200 to 1.77228 in.)
    Mark 3
    		45.017 to 45.024 mm (1.77232 to 1.77259 in.)

    Standard Connecting Rod Bearing Thickness:
    Mark
    		Specified Condition
    Mark 1
    		1.492 to 1.495 mm (0.0587 to 0.05886 in.)
    Mark 2
    		1.496 to 1.498 mm (0.05890 to 0.05898 in.)
    Mark 3
    		1.499 to 1.501 mm (0.05902 to 0.0591 in.)

    Standard Crankshaft Pin Diameter:
    Mark
    		Specified Condition
    Mark 1, 2, 3
    		41.992 to 42.000 mm (1.6532 to 1.6535 in.)



12. INSPECT CONNECTING ROD BOLT


    A036651E06

  1. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.
    Text in Illustration 
    *a
    		Measurement Area

    Standard diameter:
    6.6 to 6.7 mm (0.2598 to 0.2638 in.)

    Minimum diameter:
    6.4 mm (0.2520 in.)

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



13. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    A199963E03

  1. Using a vernier caliper, measure the length of the bolts.
    Text in Illustration 
    *a
    		Measurement Length

    Standard bolt length:
    75.3 to 76.7 mm (2.965 to 3.020 in.)

    Maximum bolt length:
    77.2 mm (3.039 in.)

    If the bolt length is greater than the maximum, replace the bolt.



    A209623E03

  1. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.
    Text in Illustration 
    *a
    		Measurement Area

    Standard bolt diameter:
    9.94 to 9.96 mm (0.3914 to 0.3921 in.)

    Minimum bolt diameter:
    9.6 mm (0.377 in.)

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



14. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

  1. Check the oil nozzles for damage or clogging.

    HINT:
    If there is damage or clogging, replace the oil nozzle.