Cylinder Block Assembly: Testing and Inspection

1UR-FSE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

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 oil nozzle.

(b) While covering A, apply air into B. Then check the oil nozzle for damage or clogging.

If there is an air leak, clean or replace the oil nozzle.

HINT
Cover B and apply air into A. Perform the check again.

(c) Push the check valve while covering A, and apply air into B. Check that air passes through the oil nozzle.

If air cannot pass through, clean or replace the oil nozzle.

HINT
Cover B and, while pushing the check valve, apply air into A. Perform the check again.

2. INSPECT CYLINDER BLOCK FOR WARPAGE

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

Maximum warpage:

0.07 mm (0.0028 in.)

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

(b) 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 BORE

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

Standard diameter:

94.000 to 94.012 mm (3.7008 to 3.77013 in.)

Maximum diameter:

94.200 mm (3.7087 in.)

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

4. INSPECT PISTON SUB-ASSEMBLY WITH PIN

(a) Using a micrometer, measure the piston diameter at a position that is 10.7 mm (0.421 in.) below the center of the piston pin hole (refer to the illustration).

Standard diameter:

93.955 to 93.965 mm (3.6990 to 3.6994 in.)

Minimum diameter:

93.830 mm (3.6941 in.)

5. 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 (0.0014 to 0.0022 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.

6. 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.

7. 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 (2.362 in.) from the top of the cylinder block.

Standard end gap:

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.

8. 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.

Standard piston pin hole inside diameter:

Standard piston pin diameter:

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

Standard oil clearance:

-0.002 to 0.004 mm (-0.0001 to 0.0002 in.)

Maximum oil clearance:

0.015 mm (0.0006 in.)

HINT
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 (0.0002 to 0.0004 in.)

Maximum oil clearance:

0.03 mm (0.0012 in.)

HINT
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the connecting rod and piston pin as a set.

9. 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 (0.0020 in.) per 100 mm (3.937 in.)

If the bend is greater than the maximum, replace the connecting rod.

(2) Check for twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.937 in.)

If the twist is greater than the maximum, replace the connecting rod.

10. 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.

11. 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 (0.0004 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.

(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 (2.0859 to 2.0866 in.)

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

12. 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.

HINT
Tape the screwdriver tip before use.

NOTICE:
* Pry up the main bearing caps little by little to the right and left in turns.
* Be careful not to damage the joint surface of the cylinder block and main bearing caps.

(d) Clean each main journal and bearing.

(e) Check each main journal and bearing for pitting and scratches.

HINT
If the journal or bearing is damaged, replace the bearing.

(f) Place the crankshaft on the cylinder block.

(g) Lay a strip of Plastigauge across each journal.

(h) 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.

(i) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(j) Place the crankshaft bearing cap on the cylinder block.

(k) Temporarily install the 10 main bearing cap bolts to the inside positions.

(l) Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Bolt length:

91 mm (3.583 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 main bearing cap bolts.

(o) Temporarily install the 10 main bearing cap bolts to the outside positions.

Bolt length:

79.5 mm (3.130 in.)

HINT
The main bearing cap bolts are tightened in 2 progressive steps.

(p) Step 1:

(1) Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.

Torque : 61 Nm (622 kgf-cm, 45 ft-lbf) for inside position

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf) for outside position

If any of the main bearing cap bolts does not meet the specified torque, replace it.

NOTICE:
Do not turn the crankshaft.

(q) Step 2:

(1) Mark the front of each bearing cap bolt with paint.

(2) Tighten the bearing cap bolts another 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 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration.

Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)

(s) Remove the 30 bolts and bearing caps.

(t) Measure the Plastigauge at its widest point.

Standard oil clearance:

Maximum oil clearance:

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

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")

Standard crankshaft main journal diameter:

Standard bearing center wall thickness for No. 1 and No. 5 journals:

Standard bearing center wall thickness for other journals:

(u) Completely remove the Plastigauge.

13. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.

Standard diameter:

10.8 to 11.0 mm (0.425 to 0.433 in.) for bolt A

9.8 to 10.0 mm (0.386 to 0.394 in.) for bolt B

Minimum diameter:

10.7 mm (0.421 in.) for bolt A

9.7 mm (0.382 in.) for bolt B

Measuring point:

47 mm (1.850 in.)

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