Cylinder Block Inspection/Repair
CYLINDER BLOCK INSPECTION
1. Measure the distortion of the cylinder block top surface in the six directions as indicated in the figure.
- If not as specified, replace the cylinder block.
Cylinder block maximum distortion: 0.08 mm (0.0031 inch)
2. Measure the cylinder bores in X and Y directions at 50 mm (12.0 inch) below the top surface.
- If the difference between measurements A and C exceeds the maximum taper, replace the cylinder block.
- If the difference between measurements X and Y exceeds the maximum out-of-round, replace the cylinder block.
Cylinder bore
Maximum taper: 0.006 mm (0.0002 inch)
Out-of-round: 0.020 mm (0.00079 inch)
WATER INLET TUBE INSTALLATION
1. When replacing the cylinder block that has no water inlet tube, install the water inlet tube after applying sealant using the SST
Thickness: 2.0 mm (0.079 inch)
PISTON INSPECTION
1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 42.6 mm 11.68 inch) below the top of the piston. If the piston diameter is below the standard diameter, replace the piston.
Piston diameter
PISTON CLEARANCE INSPECTION
1. Measure the piston-to-cylinder clearance.
- If not as specified, replace the piston or the cylinder block.
- If the piston is replaced, the piston rings must also be replaced.
Standard clearance: -0.012 - 0.022 mm (-0.0004 - 0.0008 inch)
PISTON RING CLEARANCE INSPECTION
1. Measure the piston ring-to-ring groove clearance around the entire circumference. If the piston ring-to-ring groove clearance exceeds the maximum clearance, replace the piston and piston ring.
Standard clearance
Top: 0.0430 - 0.075 mm (0.0016 - 0.0029 inch)
Second: 0.0430 - 0.085 mm (0.00106 - 0.0033 inch)
Maximum clearance: 0.510 mm (0.0039 inch)
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
3. Measure each piston ring end gap with a feeler gauge.
- If the piston ring end gap exceeds the maximum end gap, replace the piston ring.
Standard end gap
Top: 0.510 - 0.25 mm (0.004 - 0.009 inch)
Second: 0.27 - 0.42 mm (0.011 - 0.016 inch)
Oil (rail): 0.15 - 0.65 mm (0.006 - 0.025 inch)
Maximum end gap
Top: 0.550 mm (0.019 inch)
Second: 0.65 mm (0.025 inch)
Oil (rail): 0.590 mm (0.035 inch)
PISTON PIN CLEARANCE INSPECTION
1. Measure each piston pin bore diameter in X and Y directions at the four points (A, B, C, and D) as indicated in the figure.
Standard diameter: 21.015 - 21.020 mm (0.82737 - 0.582755 inch)
2. Measure each connecting rod small end inner diameter in X and Y directions as indicated in the figure.
Standard diameter: 21.017 - 21.031 mm (0.582744 - 0.582799 inch)
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C and D) as indicated in the figure.
Standard diameter: 21.011 - 21.013 mm (0.82721 - 0.582728 inch)
4. Calculate the piston pin-to-piston pin bore clearance.
- If not as specified, replace the piston and/or piston pin.
Standard clearance: 0.002 - 0.009 mm (0.00008 - 0.00035 inch)
5. Calculate the connecting rod small end-to-piston pin clearance.
- If the connecting rod small end-to-piston pin clearance exceeds the maximum clearance, replace the piston or piston pin.
Standard clearance: 0.004 - 0.020 mm (0.00016 - 0.00078 inch)
Maximum clearance: 0.035 mm (0.0013 inch)
CRANKSHAFT INSPECTION
1. Measure the crankshaft runout. If the crankshaft runout exceeds the maximum runout, replace the crankshaft.
Maximum runout: 0.05 mm (0.0019 inch)
2. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure.
- If not as specified, replace the crankshaft or grind the journal and install the undersize bearing.
Main journal
Crank pin
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR
1. Install the upper main bearing and crankshaft.
2. Position a plastigage atop the journals in the axial direction.
3. Install the lower main bearing and lower cylinder block, and tighten the bolts in the order indicated in the figure.
Tightening torque: 37 - 43 Nm (3.7 - 4.4 kgf-m, 27 - 31 ft. lbs.)
4. Tighten the bolts by turning each 85° - 95° in the sequence as indicated in the figure.
5. Loosen the bolts in the reverse order of tightening.
6. Measure the main journal oil clearance.
- If not as specified, replace the main bearing using the main bearing selection table or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.
Standard clearance: 0.025 - 0.050 mm (0.0010 - 0.00109 inch)
Main bearing selection table
Example of main bearing selection
CRANKSHAFT END PLAY INSPECTION
1. Measure the crankshaft end play.
- If not as specified, replace the thrust bearing and No.4 lower main bearing or crankshaft so that the specified end play is obtained.
Standard end play: 0.5110 - 0.232 mm (0.00434 - 0.00913 inch)
CONNECTING ROD INSPECTION
1. Measure each connecting rod for bending and distortion.
- If not as specified, replace the connecting rod.
Bending: 0.038 mm (0.0014 in) max./25 mm (0.598 inch)
Distortion: 0.050 mm (0.0019 in) max./25 mm (0.598 inch)
Center-to-center distance: (138.06 - 138.40 mm (5.4355 - 5.4488 inch)
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR
1. Position plastigage atop the journals in the axial direction.
2. Install the connecting rod bearing and connecting rod cap.
3. Remove the connecting rod cap.
4. Measure the connecting rod oil clearance.
- If not as specified, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained.
Standard clearance: 0.028 - 0.066 mm (0.00102 - 0.0025 inch)
CONNECTING ROD SIDE CLEARANCE INSPECTION
1. Measure the connecting rod large end side clearance.
- If the connecting rod side clearance exceeds the maximum clearance, replace the connecting rod and cap.
Standard clearance: 0.510 - 0.530 mm (0.004 - 0.011 inch)
Maximum clearance: 0.535 mm (0.013 inch)