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Inspection [10/2015 - ]: Procedure

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  1. INSPECT CYLINDER BLOCK FOR WARPAGE 
    1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head gasket.
      GTY632902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Warpage

      0.05 mm (0.00197 in.)

      If the warpage is more than the maximum, replace the cylinder block sub-assembly.

  2. INSPECT CYLINDER BORE 
    1. Using a cylinder gauge, measure the cylinder bore diameter at positions (A) and (B) in the thrust and axial directions.
      GTY623701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Thrust Direction
      *b Axial Direction
      *c Center
      *d 10 mm (0.394 in.)
      Front of Engine

      Reference Valve (new parts)

      86.000 to 86.013 mm (3.3858 to 3.3863 in.)

      Maximum Diameter

      86.13 mm (3.3909 in.)

      If the average diameter of the 4 positions is more than the maximum, replace the cylinder block sub-assembly.

  3. INSPECT PISTON 
    1. Using a gasket scraper, remove any carbon from the piston top.
    2. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
    3. Using a brush and solvent, thoroughly clean the piston.
      NOTE:

      Do not use a wire brush.

    4. Using a micrometer, measure the piston diameter at a right angle to the piston center line where the distance from the bottom of the piston is as specified.
      GTY495464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Distance

      Distance

      10.4 mm (0.409 in.)

      Reference Piston Diameter (New Parts)

      85.960 to 85.972 mm (3.384 to 3.385 in.)

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

  4. INSPECT PISTON OIL CLEARANCE 
    1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

      Reference Value (new parts)

      0.030 to 0.053 mm (0.00118 to 0.00209 in.)

      Maximum Oil Clearance

      0.10 mm (0.00394 in.)

      If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly.

  5. INSPECT RING GROOVE CLEARANCE 
    1. Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove.

      Standard Ring Groove Clearance

      Item Specified Condition
      No. 1 Compression Ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
      No. 2 Compression Ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
      Oil Ring 0.070 to 0.150 mm (0.00276 to 0.00591 in.)

      If the groove clearance is not as specified, replace the piston with piston pin.

  6. INSPECT 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, 120 mm (4.72 in.) from the top of the cylinder block sub-assembly.
    3. Using a feeler gauge, measure the end gap.

      Standard End Gap

      Item Specified Condition
      No. 1 Compression Ring 0.18 to 0.25 mm (0.00709 to 0.00984 in.)
      No. 2 Compression Ring 0.65 to 0.75 mm (0.0256 to 0.0295 in.)
      Oil Ring (Side Rail) 0.10 to 0.35 mm (0.00394 to 0.0138 in.)

      Maximum End Gap

      Item Specified Condition
      No. 1 Compression Ring 0.85 mm (0.0335 in.)
      No. 2 Compression Ring 1.35 mm (0.0531 in.)
      Oil Ring (Side Rail) 0.95 mm (0.0374 in.)

      If the end gap is more than the maximum, replace the compression ring. If the end gap is more than the maximum even with a new compression ring, replace the cylinder block sub-assembly.

  7. INSPECT PISTON PIN OIL CLEARANCE 
    1. Check each mark on the piston, piston pin and connecting rod.
      GTY502127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark *b Position Pin Hole Inside Diameter Mark
      *c Connecting Rod Small End Bush Inside Diameter Mark - -
    2. Using a caliper gauge, measure the inside diameter of the piston pin hole.

      Standard Piston Pin Hole Inside Diameter

      Mark Specified Condition
      A 24.001 to 24.004 mm (0.94492 to 0.94504 in.)
      B 24.005 to 24.007 mm (0.94508 to 0.94516 in.)
      C 24.008 to 24.010 mm (0.94520 to 0.94527 in.)
    3. Using a micrometer, measure the piston pin diameter.
      GTY375279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 mm (0.197 in.)
      *b 28 mm (1.10 in.)

      Standard Piston Pin Diameter

      Mark Specified Condition
      A 23.997 to 24.000 mm (0.94476 to 0.94488 in.)
      B 24.001 to 24.003 mm (0.94492 to 0.94500 in.)
      C 24.004 to 24.006 mm (0.94504 to 0.94512 in.)

      If the diameter is not as specified, replace the piston pin.

    4. Using a caliper gauge, measure the connecting rod small end bush inside diameter.

      Standard Connecting Rod Small End Bush Inside Diameter

      Mark Specified Condition
      A 24.005 to 24.008 mm (0.94508 to 0.94520 in.)
      B 24.009 to 24.011 mm (0.94523 to 0.94531 in.)
      C 24.012 to 24.014 mm (0.94535 to 0.94543 in.)

      If the diameter is not as specified, replace the connecting rod.

    5. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

      Standard Oil Clearance

      0.001 to 0.007 mm (0.0000394 to 0.000276 in.)

      Maximum Oil Clearance

      0.013 mm (0.000512 in.)

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

    6. Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement.

      Standard Oil Clearance

      0.005 to 0.011 mm (0.000197 to 0.000433 in.)

      Maximum Oil Clearance

      0.017 mm (0.000669 in.)

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

  8. INSPECT CONNECTING ROD 
    1. Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.
      GTY170517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check for misalignment.

        Maximum Misalignment

        0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

        If the misalignment is more than the maximum, replace the connecting rod.

      2. Check for twist.
        GTY194965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Maximum Twist

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

        If the twist is more than the maximum, replace the connecting rod.

  9. INSPECT CRANKSHAFT 
    1. Inspect for runout.
      1. Using a dial indicator and V-blocks, measure the runout.

        Maximum Runout

        0.03 mm (0.00118 in.)

        If the runout is more than the maximum, replace the crankshaft.

    2. Inspect the main journals.
      GTY520381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the diameter of each main journal.

        Standard Main Journal Diameter

        54.988 to 55.000 mm (2.1649 to 2.1654 in.)

        If the diameter is not as specified, check the crankshaft 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

        0.003 mm (0.000118 in.)

        If the taper or out-of-round are more than the maximum, replace the crankshaft.

    3. Inspect the crank pin.
      GTY520385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the diameter of each crank pin.

        Standard Crank Pin Diameter

        51.492 to 51.500 mm (2.0272 to 2.0276 in.)

        If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft.

      2. Inspect each crank pin for taper and out-of-round as shown in the illustration.

        Maximum Taper and Out-of-round

        0.003 mm (0.000118 in.)

        If the taper or out-of-round are more than the maximum, replace the crankshaft.

  10. INSPECT CRANKSHAFT OIL CLEARANCE 
    1. Install the crankshaft bearings.

      See step  6

    2. Install the crankshaft thrust washers.

      See step  7

    3. Clean each main journal and crankshaft bearing.
      GTY633682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    4. Place the crankshaft onto the cylinder block sub-assembly.
    5. Lay a strip of Plastigage across each journal.
    6. Install the crankshaft bearing caps.

      See step  8

      NOTE:

      Do not turn the crankshaft.

    7. Remove the crankshaft bearing caps.

      See step  6

    8. Measure the Plastigage at its widest point.
      GTY641506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage

      Standard Oil Clearance

      0.018 to 0.042 mm (0.000709 to 0.00165 in.)

      Maximum Oil Clearance

      0.050 mm (0.00197 in.)

      NOTE:

      Remove the Plastigage completely after the measurement.

      If the oil clearance is more than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

      HINT: 

      If replacing a crankshaft bearing, select a new one with the same number. If the number of the crankshaft bearing cannot be determined, select the correct crankshaft bearing number by adding together the numbers imprinted on the cylinder block sub-assembly and crankshaft. Then refer to the following table for the appropriate crankshaft bearing number. There are 4 sizes of standard bearings, marked "1", "2", "3" or "4" accordingly.

      GTY672058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder Block Number Mark (A) *b Crankshaft Number Mark (B)
      *c Diameter Mark *d No. 1
      *e No. 2 *f No. 3
      *g No. 4 *h No. 5
      1. EXAMPLE

        Cylinder block sub-assembly (A) "3" + Crankshaft (B) "4" = Total "7"

        Select the bearing marked "3".

        Bearing Chart

        (A) + (B) Bearing to be Used
        0 to 2 1
        3 to 5 2
        6 to 8 3
        9 to 11 4

        Standard Cylinder Block Journal Inside Diameter (A)

        Mark Specified Condition
        0 59.000 to 59.002 mm (2.32283 to 2.32291 in.)
        1 59.003 to 59.004 mm (2.32295 to 2.32299 in.)
        2 59.005 to 59.006 mm (2.32303 to 2.32307 in.)
        3 59.007 to 59.009 mm (2.32311 to 2.32318 in.)
        4 59.010 to 59.011 mm (2.32322 to 2.32326 in.)
        5 59.012 to 59.013 mm (2.32330 to 2.32334 in.)
        6 59.014 to 59.016 mm (2.32338 to 2.32346 in.)

        Standard Crankshaft Main Journal Diameter (B)

        Mark Specified Condition
        0 54.999 to 55.000 mm (2.16531 to 2.16535 in.)
        1 54.997 to 54.998 mm (2.16523 to 2.16527 in.)
        2 54.995 to 54.996 mm (2.16515 to 2.16519 in.)
        3 54.993 to 54.994 mm (2.16507 to 2.16511 in.)
        4 54.991 to 54.992 mm (2.16500 to 2.16504 in.)
        5 54.988 to 54.990 mm (2.16488 to 2.16496 in.)

        Standard Crankshaft Bearing (Silver) Center Wall Thickness

        Mark Specified Condition
        1 1.991 to 1.994 mm (0.07839 to 0.07850 in.)
        2 1.995 to 1.997 mm (0.07854 to 0.07862 in.)
        3 1.998 to 2.000 mm (0.07866 to 0.07874 in.)
        4 2.001 to 2.003 mm (0.07878 to 0.07886 in.)

        Standard Crankshaft Bearing (Black) Center Wall Thickness

        Mark Specified Condition
        1 1.992 to 1.995 mm (0.07843 to 0.07854 in.)
        2 1.996 to 1.998 mm (0.07858 to 0.07866 in.)
        3 1.999 to 2.001 mm (0.07870 to 0.07878 in.)
        4 2.002 to 2.004 mm (0.07882 to 0.07890 in.)
    9. Perform the inspection above for each journal.
  11. INSPECT CRANKSHAFT BEARING CAP BOLT 
    1. Type A:
      1. Using a vernier caliper, measure the diameter of the tension portion of the crankshaft bearing cap bolts.

        Measuring Point

        45 to 59 mm (1.77 to 2.32 in.)

        Standard Diameter

        10.8 to 11.0 mm (0.425 to 0.433 in.)

        Minimum Diameter

        10.7 mm (0.421 in.)

        HINT: 

        Diameter measurements should be done at several points.

        If the diameter is less than the minimum, replace the crankshaft bearing cap bolt.

        GTY501240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measuring Point
        *b Measuring Area
        *c 59 mm (2.32 in.)
        *d 45 mm (1.77 in.)
    2. Type B:
      1. Using a vernier caliper, measure the diameter of the tension portion of the crankshaft bearing cap bolts.

        Measuring Point

        45 to 59 mm (1.77 to 2.32 in.)

        Standard Diameter

        10.8 to 11.0 mm (0.425 to 0.433 in.)

        Minimum Diameter

        10.7 mm (0.421 in.)

        HINT: 

        Diameter measurements should be done at several points.

        If the diameter is less than the minimum, replace the crankshaft bearing cap bolt.

        GTY813466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measuring Point
        *b Measuring Area
        *c 59 mm (2.32 in.)
        *d 45 mm (1.77 in.)
  12. INSPECT CONNECTING ROD BOLT 
    1. Using a vernier caliper, measure the outer diameter at position A shown in the illustration.
      GTY518889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Area B
      *b 5.0 mm (0.197 in.)
      *c 10 mm (0.394 in.)
      Measurement Location A

      Standard Diameter

      8.86 to 9.00 mm (0.349 to 0.354 in.)

    2. Using a vernier caliper, measure the outer diameter within range B shown in the illustration at several locations.

      HINT: 

      • Perform the measurement within range B at several locations.
      • If the threads of the connecting rod bolt are damaged, replace the bolt with a new one.
    3. Calculate the difference between the measurement at position A and position B.

      Minimum Diameter

      The outer diameter difference is 0.15 mm (0.00591 in.)

      HINT: 

      • Outer Diameter Difference = Position A Outer Diameter - Position B Outer Diameter (Smallest Value)
      • If the outer diameter is below the minimum, the engine may be damaged.

        Therefore, replace the connecting rod bolt with a new one.

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