Cylinder Block Assembly: Testing and Inspection

1GR-FE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

1. CLEAN CYLINDER BLOCK SUB-ASSEMBLY

(a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

(b) Using a soft brush and solvent, thoroughly clean the cylinder block.

NOTICE:
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.

2. INSPECT CYLINDER BLOCK FOR WARPAGE

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

Maximum warpage:

0.05 mm (0.00197 in.)

(b) If the warpage is more than the maximum, replace the cylinder block.

(c) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 6 cylinders.

If necessary, replace the cylinder block.

3. 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 (3.7008 to 3.7013 in.)

Maximum diameter:

94.132 mm (3.7060 in.)

Measurement position (A):

10 mm (0.394 in.)

(b) If the diameter is more than the maximum, replace the cylinder block.

4. 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:

(b) If the clearance is not as specified, replace the piston with pin sub-assembly.

5. 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, 110 mm (4.33 in.) from the top of the cylinder block.

(c) Using a feeler gauge, measure the end gap.

Standard End Gap:

Maximum End Gap:

(d) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, rebore all 6 cylinders or replace the cylinder block sub-assembly.

6. CLEAN PISTON WITH PIN SUB-ASSEMBLY

(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.

NOTICE:
Do not use a wire brush.

7. INSPECT PISTON OIL CLEARANCE

(a) Using a micrometer, measure the piston diameter at a position that is 9.6 mm (0.378 in.) from the bottom of the piston (refer to the illustration).

Piston diameter:

93.961 to 93.991 mm (3.6992 to 3.7004 in.)

(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.009 to 0.051 mm (0.000354 to 0.00201 in.)

Maximum oil clearance:

0.110 mm (0.00433 in.)

(c) If the oil clearance is more than the maximum, replace all 6 pistons. If necessary, replace the cylinder block.

8. INSPECT PISTON PIN OIL CLEARANCE

(a) Check each mark on the piston and connecting rod.

(b) Using a caliper gauge, measure the inside diameter of the piston pin hole.

Standard Piston Pin Hole Inside Diameter:

Measurement Position:

Standard Piston Pin Diameter:

(d) Using a caliper gauge, measure the inside diameter of the connecting rod bush.

Standard Bush Inside Diameter:

(e) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.

Standard oil clearance:

0.001 to 0.007 mm (0.0000394 to 0.000276 in.)

Maximum oil clearance:

0.040 mm (0.00157 in.)

(f) If the oil clearance is more than the maximum, replace the piston with pin sub-assembly.

(g) 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:

0.050 mm (0.00197 in.)

(h) If the oil clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, 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.)

(2) If the bend is more than the maximum, replace the connecting rod sub-assembly.

(3) Check for twist.

Maximum twist:

0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

(4) If the twist is more than the maximum, replace the connecting rod sub-assembly.

10. INSPECT CRANKSHAFT

(a) Using a dial indicator, measure the runout at the center journal.

Maximum circle runout:

0.06 mm (0.00236 in.)

(b) If the circle runout is more than the maximum, replace the crankshaft.

(c) Using a micrometer, measure the diameter of each main journal.

Standard diameter:

71.988 to 72.000 mm (2.8342 to 2.8346 in.)

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

(e) 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.)

(f) If the taper and out-of-round is more than the maximum, replace the crankshaft.

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

Standard diameter:

55.992 to 56.000 mm (2.2044 to 2.2047 in.)

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

(i) 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.)

(j) If the taper and out-of-round is more than the maximum, replace the crankshaft.

11. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, 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.)

(b) If the diameter is less than the minimum, replace the connecting rod bolt.

12. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the thread outside diameter of the crankshaft bearing cap set bolt.

Standard diameter:

10.0 to 10.2 mm (0.394 to 0.402 in.)

(b) If the result is not as specified, replace the crankshaft bearing cap set bolt.

13. 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) 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.

(c) While covering A, blow air into B. Check that air does not leak through C. Perform the check again while covering B and blowing air into A.

If air leaks, clean or replace the oil nozzle.

(d) Push the check valve while covering A, and blow air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and blowing air into A.

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