Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (Continued)

25. INSPECT VALVE LIFTER OIL CLEARANCE

(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.

Lifter bore diameter:

31.009 to 31.025 mm (1.2208 to 1.2215 in.)

(b) Subtract the valve lifter diameter measurement (Step 16) from the lifter bore diameter measurement.

Standard oil clearance:

0.033 to 0.059 mm (0.0013 to 0.0023 in.)

Maximum oil clearance:

0.08 mm (0.0031 in.)

(c) If the oil clearance is greater than the maximum, replace the valve lifter.

If necessary, replace the cylinder head.

26. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the camshaft bearing caps, camshaft bearings and camshaft journals.

(b) Install the camshaft bearing Removal or Removal).

(c) Place the camshaft on the cylinder head.

(d) Lay a strip of Plastigage across each camshaft journal.

(e) Install the camshaft bearing caps Components or Removal).

NOTICE:
Do not turn the camshafts.

(f) Remove the camshaft bearing caps Removal or Removal).

(g) Measure the Plastigage at its widest point.

Standard oil clearance (Cylinder head RH):

Standard oil clearance (Cylinder head LH):

Maximum oil clearance (Cylinder head RH):

Maximum oil clearance (Cylinder head LH):

0.10 mm (0.0039 in.)

(h) If the oil clearance is greater than the maximum, replace the camshaft bearings and/or camshafts.

If necessary, replace the camshaft bearing caps and cylinder head together.

Reference:

(i) Remove the Plastigage completely.

(j) Remove the camshafts.

(k) Remove the camshaft bearing.

27. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshafts. Removal or Removal).

(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Standard thrust clearance:

0.04 to 0.09 mm (0.016 to 0.035 in.)

Maximum thrust clearance:

0.11 mm (0.0043 in.)

(c) If the thrust clearance is greater than the maximum, replace the camshafts.

If necessary, replace the camshaft bearing caps and cylinder head as a set.

28. 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.)

29. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct assembly.

(b) Remove the 2 connecting rod cap bolts.

(c) Clean the crank pin, bearing and connecting rod.

(d) Check the crank pin and bearing for any 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 in the correct direction.

(g) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(h) Tighten the bolts alternately to the specified torque.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

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

(j) Retighten the cap bolts 90° as shown in the illustration.

NOTICE:
Do not turn the crankshaft.

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

(l) Measure the plastigage at its widest point.

Standard oil clearance:

0.026 to 0.046 mm (0.0010 to 0.0018 in.)

Maximum oil clearance:

0.066 mm (0.0025 in.)

NOTICE:
Completely remove the plastigage.

(m) When replacing the bearing, replace it with one with the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1 ", "2", "3" and "4" accordingly.

HINT
Standard bearing center wall thickness

30. CHECK CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

Maximum warpage:

0.05 mm (0.0020 in.)

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

31. 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:

94.132mm (3.7060 in.)

(b) If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.

32. INSPECT WITH PISTON SUB-ASSEMBLY

(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 in.) from the piston head.

Piston diameter:

93.910 to 93.940 mm (3.6972 to 3.6984 in.)

33. INSPECT PISTON OIL CLEARANCE

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

Standard oil clearance:

0.060 to 0.102 mm (0.0031 to 0.0040 in.)

Maximum oil clearance:

0.13 mm (0.0051 in.)

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

34. 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.)

(2) If misalignment is greater than the maximum, replace the connecting rod assembly.

(3) Check the twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

(4) If the twist is greater than the maximum, replace the connecting rod assembly.

35. INSPECT PISTON PIN OIL CLEARANCE

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

Piston pin hole internal diameter:

22.001 to 22.010 mm (0.8662 to 0.8665 in.)

Piston pin hole inside diameter:

(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter:

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

Piston pin diameter:

Bushing internal diameter:

22.005 to 22.014 mm (0.8663 to 0.8667 in.)

Bushing internal diameter:

(d) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement.

Standard oil clearance:

0.001 to 0.007 mm (0.00004 to 0.00028 in.)

Maximum oil clearance:

0.040 mm (0.0016 in.)

(e) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and piston pin together.

(f) 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:

0.050 mm (0.0020 in.)

(g) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together.

36. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Ring groove clearance:

No.1 0.02 to 0.07 mm (0.0008 to 0.0028 in.)

No.2 0.02 to 0.06 mm (0.0008 to 0.0024 in.)

Oil 0.07 to 0.15 mm (0.0028 to 0.0060 in.)

37. 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:

No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.)

No. 2 0.40 to 0.50 mm (0.0157 to 0.0197 in.)

Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum end gap:

No. 1 1.0 mm (0.039 in.)

No. 2 1.1 mm (0.043 in.)

Oil (Side rail) 1.0 mm (0.039 in.)

38. 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.)

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

39. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using vernier calipers, measure the tension portion diameter of the bolt.

Standard diameter:

10.0 to 10.2 mm (0.393 to 0.402 in.)

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

40. 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:

71.988 to 72.000 mm (2.8342 to 2.8346 in.)

(c) Check each main journal for taper and out-of-roundness as shown.

Maximum taper and out-of-roundness:

0.02 mm (0.0008 in.)

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

Diameter:

55.992 to 56.000 mm (2.2044 to 2.2047 in.)

(e) Check each crank pin for taper and out-of-roundness as shown.

Maximum taper and out-of-roundness:

0.02 mm (0.0008 in.)

41. INSPECT CRANKSHAFT OIL CLEARANCE

HINT
There are 2 types of main bearings with different widths (19.0 mm (0.748 in.) and 22.4 mm (0.882 in.)) for use in the inspection. Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean each main journal and bearing.

(b) Install the 4 upper bearings.

(1) Install the upper bearing near the center of the cylinder block.

NOTICE:
* The width of the No. 1 and No. 4 journal bearings is different from that of the No. 2 and No. 3 journal bearings. Therefore, confirm whether it is the correct journal bearing prior to installation.
* Do not apply engine oil to the bearing installation surfaces of the cylinder block and the back side of the bearings.
* Check that the oil groove on the cylinder block can be seen through the oil supply holes of the upper bearing.
(c) Install the 4 lower bearings.

(1) Install the lower bearing near the center of the cylinder block.

NOTICE:
Do not apply engine oil to the bearing and its contact surface.

HINT
A number marked on each main bearing cap indicates 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, check the sequence order is as shown and install the bearing caps onto the cylinder block.

(g) Apply a light coat of engine oil to the threads of bearing cap bolts.

(h) Temporarily install the 8 main bearing cap bolts in the inside positions.

(i) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 in.).

(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 main bearing cap bolts.

(l) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.

Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)

(m) Mark the front side of the bearing cap bolts with paint.

(n) Retighten the bearing cap bolts 90° in the sequence as shown.

(o) Check that the painted mark is now at a 90° angle from the front.

NOTICE:
Do not turn the crankshaft.

(p) Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

(q) Remove the main bearing caps.

(r) Measure the Plastigage at its widest point.

Standard oil clearance:

0.018 to 0.030 mm (0.0007 to 0.0012 in.)

Maximum clearance:

0.046 mm (0.0018 in.)

(r) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTICE:
Completely remove the plastigage.

(s) Replace the bearing with 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. There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Journal bearing:

HINT
EXAMPLE

Cylinder block "11" (A) + Crankshaft "06" (B)

=Total number 17 (Use bearing "3")