Cylinder Block Assembly: Testing and Inspection

2UZ-FE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

INSPECTION

1. INSPECT CYLINDER BLOCK SUB-ASSEMBLY





(a) Clean the cylinder block.
(1) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
(2) Using a soft brush and solvent, thoroughly clean the cylinder block.
NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.





(b) Using a precision straightedge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.
Maximum warpage:
0.07 mm (0.00276 in.)
If the warpage is greater than the maximum, replace the cylinder block.





(c) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all 8 cylinders and replace all 8 pistons. If necessary, replace the cylinder block.
2. INSPECT CYLINDER BORE
HINT: There are 3 standard cylinder bore diameter sizes, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.





(a) Inspect the cylinder bore diameter.




(1) Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Measurement position:






Standard diameter:






Maximum diameter:
94.230 mm (3.71 in.)
If the diameter is greater than the maximum, rebore all 8 cylinders and replace all 8 pistons. If necessary, replace the cylinder block.
3. INSPECT PISTON SUB-ASSEMBLY WITH PIN
(a) Clean the piston.




(1) Using a gasket scraper, remove the carbon from the piston top.




(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.




(3) Using solvent and a brush, thoroughly clean the piston.
NOTE: Do not use a wire brush.

(b) Inspect the piston oil clearance.




HINT: There are 3 standard diameter sizes, marked "1", "2" and "3". The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at a position that is 6.7 mm (0.264 in.) downward from the center of the piston pin hole (refer to the illustration).
Standard piston diameter:





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




(3) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.045 to 0.066 mm (0.00178 to 0.00259 in.)
Maximum oil clearance:
0.13 mm (0.00512 in.)
If the oil clearance is greater than the maximum, replace all 8 pistons and rebore all 8 cylinders. If necessary, replace the cylinder block.
HINT: When replacing the cylinder block, use a piston with the same number mark as the cylinder diameter marked on the cylinder block.

(c) Inspect the piston pin fit.




(1) Heat the piston to approximately 60°C (140°F), and push the piston pin into the piston pin hole with your thumb.
4. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the piston pin hole.
Standard piston pin hole inside diameter:










(b) Using a micrometer, measure the piston pin diameter.
Standard 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 (-0.0000787 to 0.000157 in.)
If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.





(d) Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Standard bush inside diameter:
22.005 to 22.014 mm (0.866 to 0.867 in.)
If the bush inside diameter is not as specified, replace the connecting rod sub-assembly and check the oil clearance.
(2) 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:
0.05 mm (0.00197 in.)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin with a new piston and pin set.
5. INSPECT PISTON RING SET





(a) Inspect the piston ring groove clearance.
(1) 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.
(b) Inspect the piston ring end gap.




(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block.




(3) 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, rebore all 8 cylinders or replace the cylinder block sub-assembly.
6. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.




(1) Check if the connecting rod is bent.
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 sub-assembly.




(2) Check if the connecting rod is twisted.
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 sub-assembly.
7. 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:
0.04 mm (0.00157 in.)
If the circle runout is greater the maximum, replace the crankshaft.





(b) Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each main journal and crank pin.
Standard diameter:






If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) Check each main journal and 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.
8. INSPECT CONNECTING ROD BOLT





(a) Using a vernier caliper, measure the tension portion of the connecting rod bolt.
Standard diameter:
7.200 to 7.300 mm (0.283 to 0.287 in.)
Minimum diameter:
7.00 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
9. INSPECT CRANKSHAFT BEARING CAP BOLT





(a) Using a vernier caliper, measure the tension portion diameter of the main bearing cap bolt.
Measuring point:
67.0 mm (2.64 in.)
Standard diameter:
10.760 to 10.970 mm (0.424 to 0.432 in.)
Minimum diameter:
10.40 mm (0.409 in.)
If the diameter is less than the minimum, replace the cap bolt.
10. 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 oil nozzle.





(b) While covering A, apply air into B. Then check the oil nozzle for damage or clogging. Perform the check again while covering B and applying air into A.
If there is an air leak, repair or replace the oil nozzle.
If the oil nozzle is clogged, clean or replace it.





(c) Push the check valve while covering A, and apply air into B. Check that air passes through the oil nozzle. Perform the check again while covering B, pushing the check valve and applying air into A.
If air cannot pass through, clean or replace the oil nozzle.