Cylinder Block Assembly: Testing and Inspection

2ZR-FXE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

1. INSPECT CYLINDER BLOCK FOR WARPAGE

(a) Using a straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head gasket.

Maximum warpage:

0.05 mm (0.00197 in.)

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

2. INSPECT CYLINDER BORE

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

Text in Illustration

Standard diameter:

80.500 to 80.513 mm (3.169 to 3.170 in.)

Maximum diameter:

80.63 mm (3.174 in.)

Measurement Position:

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

3. INSPECT PISTON

(a) Using a gasket scraper, remove the carbon from the piston top.

(b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

NOTICE:
Do not use a wire brush.

(d) Using a micrometer, measure the piston diameter at a position that is 8.0 mm (0.315 in.) from the bottom of the piston (refer to the illustration).

Standard piston diameter:

80.461 to 80.471 mm (3.1677 to 3.1681 in.)

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

4. INSPECT PISTON OIL CLEARANCE

(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.009 to 0.042 mm (0.000354 to 0.00165 in.)

Maximum oil clearance:

0.08 mm (0.00315 in.)

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

5. 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 groove clearance is not as specified, replace the piston with pin.

6. INSPECT PISTON RING END GAP

(a) 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.

(b) Using a feeler gauge, measure the end gap.

Standard End Gap:

Maximum End Gap:

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

7. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the piston pin bore diameter.

Standard piston pin bore diameter:

20.006 to 20.015 mm (0.78764 to 0.78799 in.)

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

(b) Using a micrometer, measure the piston pin diameter.

Standard piston pin diameter:

20.004 to 20.013 mm (0.78756 to 0.78791 in.)

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

Measurement Position:

Standard connecting rod small end bore diameter:

20.012 to 20.021 mm (0.78787 to 0.78823 in.)

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

(d) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.

Text in Illustration

Standard oil clearance:

-0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)

Maximum oil clearance:

0.010 mm (0.000394 in.)

If the oil clearance is more than the maximum, replace the connecting rod. If necessary, replace the piston with pin as a set.

(e) Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.

Standard oil clearance:

0.005 to 0.011 mm (0.000197 to 0.000433 in.)

Maximum oil clearance:

0.014 mm (0.000551 in.)

If the oil clearance is more than the maximum, replace the connecting rod small end bush. If necessary, replace the piston with pin as a set.

8. INSPECT CONNECTING ROD SUB-ASSEMBLY

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

(1) Check for misalignment.

Maximum misalignment:

0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

If the misalignment is more 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 more than the maximum, replace the connecting rod.

9. INSPECT CRANKSHAFT

(a) Inspect the circle runout.

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

Maximum circle runout:

0.03 mm (0.00118 in.)

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

(b) Inspect the main journals.

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

Standard diameter:

47.988 to 48.000 mm (1.8893 to 1.8898 in.)

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

(2) Check each main journal for taper and distortion as shown in the illustration.

Maximum taper and distortion:

0.004 mm (0.000157 in.)

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

Standard Diameter (Reference):

Standard diameter:

43.992 to 44.000 mm (1.7320 to 1.7323 in.)

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

(2) Inspect each crank pin for taper and distortion.

Maximum taper and distortion:

0.004 mm (0.000157 in.)

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

10. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Check the crankshaft journals and bearings for pitting and scratches.

(b) Install the crankshaft bearings Reassembly.

(c) Install the upper crankshaft thrust washers Reassembly.

(d) Clean each main journal and bearing.

(e) Place the crankshaft on the cylinder block.

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

Text in Illustration

(g) Examine the front marks and numbers and place the bearing caps on the cylinder block.

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

(h) Install the crankshaft bearing cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(i) Remove the crankshaft bearing caps Disassembly.

(j) Measure the Plastigage at its widest point.

Text in Illustration

Standard oil clearance:

0.016 to 0.039 mm (0.000630 to 0.00154 in.)

Maximum oil clearance:

0.050 mm (0.00197 in.)

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

NOTICE:
Remove the Plastigage completely after the measurement.

HINT
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 "1", "2", "3" and "4" accordingly.

* Example:

Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3")

Bearing Chart

Standard Cylinder Block Journal Bore Diameter:

Standard Crankshaft Journal Diameter:

Standard Bearing Center Wall Thickness:

11. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the length of the crankshaft bearing cap set bolt from the seat to end.

Text in Illustration

Standard bolt length:

84.3 to 85.7 mm (3.32 to 3.37 in.)

Maximum bolt length:

86.7 mm (3.41 in.)

HINT
* If the bolt length is greater than the maximum, replace the crankshaft bearing cap set bolt with a new one. Failure to do so may lead to engine damage.
* If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.

(b) Using a vernier caliper, measure the diameter of the threaded portion of the bolt at its thinnest point.

HINT
Use a straightedge to determine the thinnest point of the threaded portion of the bolt.

Measurement point:

55.0 mm (2.17 in.)

Standard diameter:

9.77 to 9.96 mm (0.385 to 0.392 in.)

Minimum diameter:

9.1 mm (0.358 in.)

HINT
* If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt with a new one. Failure to do so may lead to engine damage.
* If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.

12. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

Text in Illustration

Standard diameter:

6.6 to 6.7 mm (0.260 to 0.264 in.)

Minimum diameter:

6.4 mm (0.252 in.)

HINT
* Diameter measurements should be done at several points.
* If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.
* If there is any thread deformation, replace the connecting rod bolt with a new one.

13. 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.

(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.

(c) Apply air into A. Check that air does not leak through B.

If air leaks, clean or replace the No. 1 oil nozzle.

(d) Push the check valve while applying air into A. Check that air passes through B.

If air does not pass through B, clean or replace the No. 1 oil nozzle.