Cylinder Block Assembly: Testing and Inspection

3MZ-FE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

INSPECTION

1. INSPECT CONNECTING ROD THRUST CLEARANCE






(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance:
0.35 mm (0.0138 in.)
2. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Clean the crank pin, the bearing and the connecting rod.
(d) Check the crank pin and bearing for pits and scratches.






(e) Lay a strip of Plastigage across the crank pin.






(f) Check that the protrusion of the connecting rod cap is facing the correct direction.
(g) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.






(h) Tighten the bolts in several steps to the specified torque.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)






(i) Mark the front side of each connecting cap bolt with paint.






(j) Retighten the cap bolts by 90° as shown in the illustration.
NOTE: Do not turn the crankshaft.

(k) Remove the 2 bolts, the connecting rod cap and the lower bearing.






(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
NOTE: Completely remove the Plastigage.





(m) If replacing the bearing, replace it with one that has the same number as marked on the connecting rod.
Standard bearing center wall thickness:






NOTE: There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

3. INSPECT CYLINDER BLOCK FOR WARPAGE






(a) Using a precision straight edge and feeler gauge, measure the warpage of the contacting surface of the cylinder head gasket.
Maximum warpage:
0.05 mm (0.0020 in.)
If 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:
92.000 to 92.012 mm (3.6220 to 3.6225 in.)
Maximum diameter:
92.132 mm (3.6272 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 diameter of the piston. When measuring the diameter, attach the micrometer to a location where 13.0 mm (0.512 in.) above from the piston bottom at the right angles to the piston pin hole.
Piston diameter:
91.975 to 91.989 mm (3.6211 to 3.6216 in.)
6. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance:
0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the 6 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 PIN OIL CLEARANCE






(a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)






(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
(c) 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:
0.05 mm (0.0020 in.)
9. INSPECT PISTON RING END GAP






(a) 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.






(b) Using a feeler gauge, measure the end gap.
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.
10. INSPECT CRANKSHAFT THRUST CLEARANCE






(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft for wear, repair or replace if necessary.
HINT: Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

11. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.





(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment 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 twist is greater than the maximum, replace the connecting rod assembly.
12. INSPECT CONNECTING ROD BOLT






(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
13. INSPECT CRANKSHAFT BEARING CAP SET BOLT






(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter:
7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter:
7.2 mm (0.283 in.)
If the diameter is less than the minimum, replace the bolt.
14. INSPECT CRANKSHAFT






(a) Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout:
0.06 mm (0.0024 in.)






(b) Using a micrometer, measure the diameter of each main journal.
Diameter:
60.988 to 61.000 mm (2.4011 to 2.4016 in.)
(c) Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)






(d) Using a micrometer, measure the diameter of each crank pin.
Diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
(e) Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
15. INSPECT CRANKSHAFT OIL CLEARANCE






(a) Clean each main journal and bearing.
HINT: Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 2 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 3 and No. 4 positions.





(b) Align the bearing key with the keyway of the cylinder block, and push in the 4 upper bearings.
NOTE: Do not apply engine oil to the bearing and its contact surface.





(c) Align the bearing key with the keyway of the main bearing cap, and push in the 4 lower bearings.
NOTE: Do not apply engine oil to the bearing and its contact surface.
HINT: A number is marked on each main bearing cap to indicate the installation position.

(d) Place the crankshaft on the cylinder block.






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






(f) Examine the front marks and numbers and install the bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bearing cap bolts.
(h) Temporarily install the 8 main bearing cap bolts to the inside positions.






(i) Install the main bearing cap by hand until clearance between the cylinder block and the bearing cap becomes 6 mm (0.23 in.) or less.






(j) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(k) Apply a light coat of engine oil to the threads of the main bearing cap bolts.






(l) Using several steps, install and tighten the 16 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)






(m) Mark the front side of the bearing cap bolts with paint.
(n) Retighten the bearing cap bolts by 90° in the same sequence shown as step (l).






(o) Check that each painted mark is now at a 90° angle to the front.
NOTE: Do not turn the crankshaft.





(p) Using several steps, install and tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
(q) Remove the main bearing caps.






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





If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
NOTE: Completely remove the Plastigage.





(s) If replacing a bearing, replace it with one that has 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. The No. 1 and No. 2 journal bearings come in sizes, marked "3", "4", "5", "6" and "7". The No. 3 and No. 4 journal bearings come in 5 standard bearing sizes, marked "1", "2", "3", "4" and "5".