Cylinder Block Assembly: Testing and Inspection

2UR-GSE 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 No. 1 oil nozzle sub-assembly.

(b) While covering A, apply air into B. Then check the No. 1 oil nozzle sub-assembly for damage or clogging.

If there is an air leak, clean or replace the No. 1 oil nozzle sub-assembly.

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 No. 1 oil nozzle sub-assembly.

If air cannot pass through, clean or replace the No. 1 oil nozzle sub-assembly.

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 surface that contacts the cylinder head gasket.

Maximum warpage:

0.05 mm (0.00197 in.)

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

(b) Visually check the cylinder for vertical scratches.

If deep scratches are present, rebore all 8 cylinders.

If necessary, replace the cylinder block sub-assembly.

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 3.7013 in.)

Maximum diameter:

94.200 mm (3.7087 in.)

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

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:

93.980 to 93.990 mm (3.7000 to 3.7004 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:

0.010 to 0.032 mm (0.000394 to 0.00126 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 sub-assembly.

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 (2.36 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 sub-assembly.

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 (-0.0000787 to 0.000158 in.)

Maximum oil clearance:

0.015 mm (0.000591 in.)

HINT
If the oil clearance is greater than the maximum, replace the piston with pin sub-assembly.

(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:

0.030 mm (0.00118 in.)

HINT
If the oil clearance is greater than the maximum, replace the piston with pin sub-assembly.

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 (0.00197 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.

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 (0.000394 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 (2.63731 to 2.63779 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 (2.08590 to 2.08661 in.)

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

12. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Clean each main journal and bearing.

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

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

(c) Install the crankshaft bearing.

HINT
Reassembly.)

(d) Install the crankshaft thrust washer set.

HINT
Reassembly.)

(e) Place the crankshaft on the cylinder block.

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

(g) 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.

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

(i) Place the crankshaft bearing caps onto the cylinder block.

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

(k) Insert the main bearing caps by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal bearing cap bolts as a guide.

Bolt length:

91 mm (3.58 in.)

(l) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

(m) Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts.

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

Bolt length:

79.5 mm (3.13 in.)

HINT
Tighten the main bearing cap bolts in 2 progressive steps.

(o) 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.

(p) 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.

(q) 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)

(r) Remove the 30 bolts and bearing caps.

(s) Measure the Plastigage 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:

(t) Completely remove the Plastigage.

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 (1.85 in.)

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