Cylinder Block Assembly: Testing and Inspection

2UR-FSE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

INSPECTION
HINT: When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

1. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Push the check valve with a pin to check if it is stuck.
If stuck, replace the No. 1 oil nozzle sub-assembly.
(b) Push the check valve with a pin to check if it moves smoothly.
If it does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly.

(c) While covering A, apply air into B. Check that air does not leak through C. Perform the check again while covering B and applying air into A.
If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

(d) Push the check valve while covering A, and apply air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and applying air into A.
If air does not pass through C, clean or replace the No. 1 oil nozzle sub-assembly.
2. CHECK CYLINDER BLOCK SUB-ASSEMBLY

(a) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all 8 cylinders.
If necessary, replace the cylinder block.
3. INSPECT CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straightedge and feeler gauge, measure the warpage of the surfaces where the cylinder head gaskets contact the cylinder block.
Maximum warpage:
0.05 mm (0.00197 in.)
If the warpage is greater than the maximum, replace the cylinder block.
4. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter:
94.000 to 94.012 mm (3.700 to 3.701 in.)
Maximum diameter:
94.200 mm (3.709 in.)
If the diameter is greater than the maximum, replace the cylinder block.
5. INSPECT PISTON SUB-ASSEMBLY WITH PIN

(a) Using a micrometer, measure the piston diameter at a position that is 5 mm (0.197 in.) below the center of the piston pin hole (refer to the illustration).
Standard diameter:
93.980 to 93.990 mm (3.7000 to 3.7004 in.)
Minimum diameter:
93.830 mm (3.6941 in.)
If the diameter is less than the minimum, replace the piston sub-assembly with pin.
6. INSPECT PISTON OIL CLEARANCE
(a) Measure the cylinder bore diameter in the thrust direction.
(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.035 to 0.057 mm (0.00138 to 0.00224 in.)
Maximum oil clearance:
0.370 mm (0.0146 in.)
If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
7. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
Standard ring groove clearance:

If the clearance is not as specified, replace the piston.
8. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.

(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.36 in.) from the top of the cylinder block.

Maximum end gap:

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.
9. INSPECT PISTON PIN OIL CLEARANCE
(a) Check each mark on the piston, piston pin and connecting rod.

(b) Using a caliper gauge, measure the inside diameter of the piston pin hole.
HINT: Measure the diameter 5 mm (0.197 in.) inward from the snap ring groove.

Standard piston pin hole inside diameter:

(d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance:
-0.002 to 0.004 mm (-0.0000787 to 0.000157 in.)
Maximum oil clearance:
0.015 mm (0.000591 in.)
If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

(e) Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Standard bush inside diameter:

(f) Subtract the piston pin diameter measurement from the bush inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum oil clearance:
0.03 mm (0.00118 in.)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the connecting rod and piston pin as a set.
10. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.

(1) Check for bend.
Maximum bend:
0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum, replace the connecting rod.

(2) Check for twist.
Maximum twist:
0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod.
11. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter:
8.5 to 8.6 mm (0.335 to 0.339 in.)
Minimum diameter:
8.3 mm (0.327 in.)
If the diameter is less than the minimum, replace the bolt.
12. INSPECT CRANKSHAFT

(a) 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:
0.01 mm (0.000394 in.)
If the circle runout is greater than the maximum, replace the crankshaft.

(b) Inspect the main journals.
(1) Using a micrometer, measure the diameter of each main journal.
Standard journal diameter:
66.988 to 67.000 mm (2.6373 to 2.6378 in.)
If the diameter is not as specified, check the 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 and out-of-round is greater than the maximum, replace the crankshaft.

(c) Inspect the crank pin.
(1) Using a micrometer, measure the diameter of each crank pin.
Standard crank pin diameter:
52.982 to 53.000 mm (2.086 to 2.087 in.)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) Check 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 and out-of-round is greater than the maximum, replace the crankshaft.
13. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration.

(b) Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration.

(c) Using a screwdriver, slightly pry up the 5 crankshaft bearing caps.
- Be careful not to damage the joint surface of the cylinder block and crankshaft bearing caps.
- Pry up the left and right side of the cap little by little.
HINT: Tape the screwdriver tip before use.

(d) Using 2 inside position crankshaft bearing cap bolts, loosen each crankshaft bearing cap by moving it forward and backward, and remove each crankshaft bearing cap.
(e) Clean each main journal and bearing.
(f) Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearing.
(g) Place the crankshaft on the cylinder block.

(h) Lay a strip of Plastigage across each journal.

(i) Examine the front marks and numbers, and install the crankshaft bearing caps on the cylinder block.
HINT: A number is marked on each crankshaft bearing cap to indicate the installation position.

(j) Apply a light coat of engine oil the threads and under the heads of the bearing cap bolts.
(k) Temporarily install the 10 crankshaft bearing cap bolts to the inside positions.

(l) Push the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block is less than 6 mm (0.236 in.).
Bolt length:
91 mm (3.58 in.)

(m) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(n) Apply a light coat of engine oil to the threads and under the heads of the 10 crankshaft bearing cap bolts.

(o) Temporarily install the 10 crankshaft bearing cap bolts to the outside positions.
Bolt length:
79.5 mm (3.13 in.)
HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps.

(p) Step 1:
(1) Uniformly tighten the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.
for inside position - Torque: 61 Nm (622 kgf-cm, 45ft-lbf)
for inside position - Torque: 27 Nm (275 kgf-cm, 20ft-lbf)
If a crankshaft bearing cap bolt does not meet the specified torque, replace it.
NOTICE:
Do not turn the crankshaft.

(q) Step 2:
(1) Mark the front of the bearing cap bolts with paint.
(2) Tighten the bearing cap bolts 90° in the order shown in step 1.
(3) Check that the painted marks are now at a 90° angle to the front.

(r) Install and uniformly tighten the 10 crankshaft bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration.
Torque: 45 Nm (459 kgf-cm, 33ft-lbf)
(s) Remove the 30 bolts and bearing caps.

(t) Measure the Plastigage at its widest point.
Standard oil clearance:

Maximum oil clearance:

If the oil clearance is greater than the maximum, perform the next step. If necessary, replace the crankshaft.
HINT: After measurement, completely remove the Plastigage.

(u) Replace the crankshaft bearing.
(1) Replace the bearing with one having the same number.

HINT: If replacing a 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. Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For other position bearings, use bearing marked 3, 4, 5, 6, 7 and 8.
- Example:
Cylinder block "07" + Crankshaft "06" = Total number 13 (Use upper bearing "6" and lower bearing "7")
A = Cylinder block number mark
B = Crankshaft number mark

Standard crankshaft main journal diameter:

Standard bearing center wall thickness No. 1 and No. 5 journal:

Standard bearing center wall thickness other journal:

14. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.
Measuring point:
47 mm (1.85 in.)
Standard diameter:

Minimum diameter:

If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt.