Cylinder Block Assembly: Testing and Inspection

3UR-FE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

1. INSPECT CYLINDER BLOCK FOR WARPAGE

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

Maximum warpage:

0.07 mm (0.00276 in.)

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

Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 8 cylinders. If necessary, replace the cylinder block.

2. 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:

94.000 to 94.012 mm (3.700 to 3.701 in.)

Maximum diameter:

94.200 mm (3.709 in.)

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

3. INSPECT RING GROOVE CLEARANCE

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.

4. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.

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.

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.

5. INSPECT PISTON SUB-ASSEMBLY WITH PIN

Using a micrometer, measure the piston diameter at a position that is 15.0 mm (0.591 in.) from the bottom of the piston (refer to the illustration).

Standard diameter:

93.950 to 93.960 mm (3.6988 to 3.6992 in.)

Minimum diameter:

93.815 mm (3.6935 in.)

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

6. 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:

0.040 to 0.062 mm (0.00157 to 0.00244 in.)

Maximum oil clearance:

0.385 mm (0.0152 in.)

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

7. 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 0.000157 in.)

Maximum oil clearance:

0.015 mm (0.000591 in.)

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 (0.000197 to 0.000433 in.)

Maximum oil clearance:

0.03 mm (0.00118 in.)

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

8. 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.

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.

9. 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:

0.06 mm (0.00236 in.)

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

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.

(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 (0.000787 in.)

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

Inspect the crank pins.

(1) Using a micrometer, measure the diameter of each crank pin.

Standard crank pin diameter:

55.982 to 56.000 mm (2.2040 to 2.2047 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 (0.000787 in.)

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

10. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Clean each main journal and bearing.

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

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

(c) Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

(d) Install the crankshaft bearing caps Reassembly.

(e) Remove the 30 bolts and bearing caps.

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 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. Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For the No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For other bearings, use bearings 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")

HINT
A = Cylinder block number mark

B = Crankshaft number mark

Standard bearing center wall thickness:

No. 1 and No. 5 journals

Other journals:

(f) Completely remove the Plastigage.

11. INSPECT CONNECTING ROD BOLT

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.

12. INSPECT CRANKSHAFT BEARING CAP SET BOLT

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

Measuring point:

54.5 mm (2.15 in.)

Standard diameter:

Minimum diameter:

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

13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

Push the check valve with a pin to check if it is stuck. If stuck, replace the oil nozzle.

(a) Push the check valve with a pin to check if it moves smoothly.

If it does not move smoothly, clean or replace the oil nozzle.

While covering A, apply air into B. Check that air does not leak through C. Perform the check again while covering B and applying air into A.

If air leaks, clean or replace the oil nozzle.

Push the check valve while covering A, and apply air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and applying air into A.

If air does not pass through C, clean or replace the oil nozzle.