Part 4

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (Continued)

35. INSPECT PISTON OIL CLEARANCE

(a) Measure the cylinder bore diameter in the thrust directions.

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

Standard oil clearance:

0.014 to 0.036 mm (0.0006 to 0.0014 in.)

Maximum oil clearance:

0.090 mm (0.0035 in.)

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

36. INSPECT RING GROOVE CLEARANCE

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

Ring groove clearance:

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

37. 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, 110 mm (4.33 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, rebore all the 6 cylinders or replace the cylinder block.

38. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the piston pin hole.

Piston pin hole inside diameter:

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

Piston pin diameter:

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

Standard oil clearance:

-0.002 to 0.004 mm (-0.00007 to 0.0001 in.)

Maximum oil clearance:

0.015 mm (0.0006 in.)

If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

(d) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

Bushing inside diameter:

(e) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Standard oil clearance:

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance:

0.030 mm (0.0012 in.)

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

39. INSPECT CONNECTING ROD

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

(1) Check for out-of-alignment.

Maximum out-of-alignment:

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

If the out-of-alignment is greater than the maximum, replace the connecting rod assembly.

(2) Check for twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

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

40. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, measure the tension portion diameter of the bolt.

Standard diameter:

7.2 to 7.3 mm (0.284 to 0.287 in.)

Minimum diameter:

7.0 mm (0.276 in.)

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

41. INSPECT CRANKSHAFT

(a) Inspect for circle runout.

(1) Clean the crank journal.

(2) Place the crankshaft on the V-blocks.

(3) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout:

0.06 mm (0.0024 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:

60.988 to 61.000 mm (2.4011 to 2.4016 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:

0.02 mm (0.0008 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.

Crankshaft pin diameter:

47.992 to 48.000 mm (1.8894 to 1.8898 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:

0.02 mm (0.0008 in.)

If the taper and out-of-round is greater than the maximum, replace the crankshaft.

42. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Check the crank journal and bearing for pitting and scratches.

(b) Install the crankshaft bearing Reassembly.

(c) Place the crankshaft on the cylinder block.

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

(e) 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.

(f) Install the main bearing cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(g) Remove the main bearing caps Disassembly.

(h) Measure the Plastigage at its widest point.

Standard oil clearance:

0.026 to 0.047 mm (0.0010 to 0.0019 in.)

Maximum oil clearance:

0.050 mm (0.0020 in.)

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

NOTICE:
Completely remove the Plastigage after the measurement.

(i) 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, then refer to the table below for the appropriate bearing number. There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Journal bearings:

HINT
EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3")

Crankshaft main journal diameter:

Standard upper bearing center wall thickness (No. 1 and No. 4 journal):

Standard lower bearing center wall thickness (No. 1 and No. 4 journal):

Standard upper bearing center wall thickness (No. 2 and No. 3 journal):

Standard lower bearing center wall thickness (No. 2 and No. 3 journal):

43. INSPECT CRANKSHAFT BEARING CAP SET BOLT

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

Standard diameter:

10.8 to 11.0 mm (0.4252 to 0.4331 in.)

Minimum diameter:

10.7 mm (0.4213 in.)

Measuring Point:

47 mm (1.85 in.)

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