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Inspection [09/2014 - 11/2017]: 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 which contact the cylinder head gaskets.
      GTY507869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge
      *b Precision Straightedge

      Standard Warpage

      0 to 0.05 mm (0 to 0.00197 in.)

      Maximum Warpage

      0.07 mm (0.00276 in.)

      HINT: 

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

  2. INSPECT CYLINDER BORE 
    1. Visually check the cylinder for vertical scratches.

      HINT: 

      • If deep scratches are present, rebore all 6 cylinders.
      • If necessary, replace the cylinder block sub-assembly.
    2. Using a cylinder gauge, measure the cylinder bore diameter at positions (A) and (B) in the thrust and axial directions.

      Reference Value (New Parts)

      94.000 to 94.012 mm (3.7008 to 3.7013 in.)

      Maximum Diameter

      94.130 mm (3.71 in.)

      GTY470119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Thrust Direction
      *b Axial Direction
      *c 10 mm (0.394 in.)
      *d Center
      Engine Front

      HINT: 

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

  3. INSPECT PISTON SUB-ASSEMBLY WITH PIN 
    1. Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the bottom of the piston is as specified.
      GTY470607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 1
      *b for Bank 2
      *c Distance

      Distance

      9.6 mm (0.378 in.)

      Reference Value (New Parts)

      93.950 to 93.960 mm (3.6988 to 3.6992 in.)

      Minimum Diameter

      93.830 mm (3.6941 in.)

      HINT: 

      If the piston diameter is less than the minimum, replace the piston sub-assembly with pin.

  4. INSPECT PISTON OIL CLEARANCE 
    1. Measure the cylinder bore diameter in the thrust directions.
    2. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

      Reference Value (New Parts)

      0.040 to 0.062 mm (0.00157 to 0.00244 in.)

      Maximum Oil Clearance

      0.090 mm (0.00354 in.)

      HINT: 

      If the oil clearance is more than the maximum, replace the piston sub-assembly with pin or cylinder block sub-assembly according to their measurement values.

  5. INSPECT RING GROOVE CLEARANCE 
    1. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
      GTY499736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge

      Standard Ring Groove Clearance

      Item Specified Condition
      No. 1 Compression Ring 0.020 to 0.070 mm (0.00079 to 0.00276 in.)
      No. 2 Compression Ring 0.020 to 0.060 mm (0.00079 to 0.00236 in.)
      Oil Ring 0.020 to 0.070 mm (0.00079 to 0.00276 in.)

      HINT: 

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

  6. INSPECT PISTON PIN OIL CLEARANCE 
    1. Check each mark on the piston and connecting rod.
      GTY520415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 1
      *b for Bank 2
      *c Front Mark
      *d Piston Pin Hole Inside Diameter Mark
      *e Connecting Rod Bushing Inside Diameter Mark
      NOTE:

      Make sure that each piston pin is installed to the same piston it was removed from.

    2. Using a caliper gauge, measure the inside diameter of the piston pin hole.
      GTY496170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Caliper Gauge

      Standard Piston Pin Hole Inside Diameter

      Mark Specified Condition
      A 21.998 to 22.001 mm (0.86606 to 0.86618 in.)
      B 22.002 to 22.004 mm (0.86622 to 0.86630 in.)
      C 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
    3. Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter

      Mark Specified Condition
      A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
      B 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
      C 22.004 to 22.006 mm (0.86630 to 0.86638 in.)
      GTY469795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 mm (0.197 in.)
      *b 28 mm (1.10 in.)
      *c 5 mm (0.197 in.)
    4. 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.)

      Maximum Oil Clearance

      0.015 mm (0.000591 in.)

      HINT: 

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

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

      Standard Bushing Inside Diameter

      Mark Specified Condition
      A 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
      B 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
      C 22.012 to 22.014 mm (0.86661 to 0.86669 in.)
      GTY496407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Caliper Gauge
    6. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

      Standard Oil Clearance

      0.005 to 0.011 mm (0.000197 to 0.000433 in.)

      Maximum Oil Clearance

      0.030 mm (0.00118 in.)

      HINT: 

      • If the oil clearance is more than the maximum, replace the connecting rod small end bush.
      • If necessary, replace the connecting rod sub-assembly and piston sub-assembly with pin.
  7. INSPECT PISTON RING END GAP 
    1. Insert the piston ring into the cylinder bore.
      GTY469052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Piston Ring
      *a Approximately 110 mm (4.33 in.)
    2. Using a piston, push the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.
    3. Using a feeler gauge, measure the piston ring end gap.
      GTY503466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge

      Standard End Gap

      Item Specified Condition
      No. 1 Compression Ring 0.23 to 0.28 mm (0.00906 to 0.01102 in.)
      No. 2 Compression Ring 0.35 to 0.40 mm (0.01378 to 0.01575 in.)
      Oil Ring 0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      Maximum End Gap

      Item Specified Condition
      No. 1 Compression Ring 0.40 mm (0.0157 in.)
      No. 2 Compression Ring 0.50 mm (0.0197 in.)
      Oil Ring 0.45 mm (0.0177 in.)

      HINT: 

      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, replace the cylinder block sub-assembly.

  8. INSPECT CONNECTING ROD SUB-ASSEMBLY 
    1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
      1. Check for misalignment.
        GTY498019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Feeler Gauge

        Maximum Misalignment

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

        HINT: 

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

      2. Check for twist.
        GTY504281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Feeler Gauge

        Maximum Twist

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

        HINT: 

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

  9. INSPECT CONNECTING ROD BOLT 
    1. Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration.

      Standard Diameter

      8.5 to 8.6 mm (0.335 to 0.339 in.)

      Minimum Diameter

      8.3 mm (0.327 in.)

      GTY459794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Area

      HINT: 

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

      HINT: 

      • Diameter measurements should be done at several points.
      • If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.
      • If there is any thread deformation, replace the connecting rod bolt with a new one.
  10. INSPECT CRANKSHAFT 
    1. Inspect runout.
      1. Clean the crank journal.
      2. Place the crankshaft on V-blocks.
      3. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.06 mm (0.00236 in.)

        HINT: 

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

    2. Inspect the main journals.
      1. Using a micrometer, measure the diameter of each main journal.
        GTY136337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Journal Diameter

        60.988 to 61.000 mm (2.4011 to 2.4016 in.)

        HINT: 

        If the diameter is not as specified, check the 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

        0.02 mm (0.000787 in.)

        HINT: 

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

    3. Inspect the crank pins.
      1. Using a micrometer, measure the diameter of each crank pin.

        Standard Crank Pin Diameter

        52.992 to 53.000 mm (2.0863 to 2.0866 in.)

        GTY145646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

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

      2. 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.)

        HINT: 

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

  11. INSPECT CRANKSHAFT OIL CLEARANCE 
    1. Check the crank journal and crankshaft bearing for pitting and scratches.
    2. Install the crankshaft bearing.

      See step  5

    3. Place the crankshaft on the cylinder block sub-assembly.
    4. Lay a strip of Plastigage across each journal.
      GTY433424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    5. Confirm the front marks and numbers to install the crankshaft bearing caps on the cylinder block sub-assembly.

      HINT: 

      A number is marked on each crankshaft bearing cap to indicate the installation position.

    6. Install the crankshaft bearing caps.

      See step  7

      NOTE:
      • Do not apply engine oil to the crankshaft bearings or crankshaft journals.
      • Do not turn the crankshaft.
    7. Remove the crankshaft bearing caps.

      See step  6

    8. Measure the Plastigage at its widest point.

      Standard Oil Clearance

      Item Specified Condition
      No. 1, No. 4 Journal 0.026 to 0.047 mm (0.00102 to 0.00185 in.)
      No. 2, No. 3 Journal 0.032 to 0.053 mm (0.00126 to 0.00209 in.)

      Maximum Oil Clearance

      Item Specified Condition
      No. 1, No. 4 Journal 0.050 mm (0.00197 in.)
      No. 2, No. 3 Journal 0.060 mm (0.00236 in.)
      GTY513495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      NOTE:

      Completely remove the Plastigage after the measurement.

      HINT: 

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

    9. If replacing a bearing, replace it with one having 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 sub-assembly and crankshaft, and then refer to the following table for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" or "5" accordingly.

      Bearing Chart

      Cylinder Block Sub-assembly (A) + Crankshaft (B) Bearing to be Used
      0 to 5 "1"
      6 to 11 "2"
      12 to 17 "3"
      18 to 23 "4"
      24 to 28 "5"
      GTY501374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Journal Bearing and No. 4 Journal Bearing *2 No. 2 Journal Bearing and No. 3 Journal Bearing
      *a 21 mm (0.827 in.) *b 18 mm (0.709 in.)
      *c Cylinder Block Main Journal Diameter Number Mark *d Crankshaft Main Journal Diameter Number Mark
      *e Bearing Number *f No. 1
      *g No. 2 *h No. 3
      *i No. 4 *j Upper Bearing
      *k Lower Bearing - -

      HINT: 

      EXAMPLE: Cylinder block sub-assembly "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3")

      Cylinder Block Main Journal Bore Diameter (A)

      Item Specified Condition
      Mark 00 66.000 mm (2.59842 in.)
      Mark 01 66.001 mm (2.59846 in.)
      Mark 02 66.002 mm (2.59850 in.)
      Mark 03 66.003 mm (2.59854 in.)
      Mark 04 66.004 mm (2.59858 in.)
      Mark 05 66.005 mm (2.59862 in.)
      Mark 06 66.006 mm (2.59866 in.)
      Mark 07 66.007 mm (2.59870 in.)
      Mark 08 66.008 mm (2.59873 in.)
      Mark 09 66.009 mm (2.59877 in.)
      Mark 10 66.010 mm (2.59881 in.)
      Mark 11 66.011 mm (2.59885 in.)
      Mark 12 66.012 mm (2.59889 in.)
      Mark 13 66.013 mm (2.59893 in.)
      Mark 14 66.014 mm (2.59897 in.)
      Mark 15 66.015 mm (2.59901 in.)
      Mark 16 66.016 mm (2.59905 in.)

      Crankshaft Main Journal Diameter (B)

      Item Specified Condition
      Mark 00 60.999 to 61.000 mm (2.40153 to 2.40157 in.)
      Mark 01 60.998 to 60.999 mm (2.40149 to 2.40153 in.)
      Mark 02 60.997 to 60.998 mm (2.40145 to 2.40149 in.)
      Mark 03 60.996 to 60.997 mm (2.40141 to 2.40145 in.)
      Mark 04 60.995 to 60.996 mm (2.40137 to 2.40141 in.)
      Mark 05 60.994 to 60.995 mm (2.40133 to 2.40137 in.)
      Mark 06 60.993 to 60.994 mm (2.40129 to 2.40133 in.)
      Mark 07 60.992 to 60.993 mm (2.40126 to 2.40129 in.)
      Mark 08 60.991 to 60.992 mm (2.40122 to 2.40126 in.)
      Mark 09 60.990 to 60.991 mm (2.40118 to 2.40122 in.)
      Mark 10 60.989 to 60.990 mm (2.40114 to 2.40118 in.)
      Mark 11 60.988 to 60.989 mm (2.40110 to 2.40114 in.)

      Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 journal)

      Item Specified Condition
      Mark 1 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
      Mark 2 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
      Mark 3 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
      Mark 4 2.510 to 2.512 mm (0.09882 to 0.09890 in.)
      Mark 5 2.513 to 2.515 mm (0.09894 to 0.09902 in.)

      Standard Lower Bearing Center Wall Thickness (No. 1 and No. 4 journal)

      Item Specified Condition
      Mark 1 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
      Mark 2 2.482 to 2.484 mm (0.09772 to 0.09780 in.)
      Mark 3 2.485 to 2.487 mm (0.09783 to 0.09791 in.)
      Mark 4 2.488 to 2.490 mm (0.09795 to 0.09803 in.)
      Mark 5 2.491 to 2.493 mm (0.09807 to 0.09815 in.)

      Standard Upper Bearing Center Wall Thickness (No. 2 and No. 3 journal)

      Item Specified Condition
      Mark 1 2.475 to 2.478 mm (0.09744 to 0.09756 in.)
      Mark 2 2.479 to 2.481 mm (0.09760 to 0.09768 in.)
      Mark 3 2.482 to 2.484 mm (0.09772 to 0.09780 in.)
      Mark 4 2.485 to 2.487 mm (0.09783 to 0.09791 in.)
      Mark 5 2.488 to 2.490 mm (0.09795 to 0.09803 in.)

      Standard Lower Bearing Center Wall Thickness (No. 2 and No. 3 journal)

      Item Specified Condition
      Mark 1 2.497 to 2.500 mm (0.09831 to 0.09843 in.)
      Mark 2 2.501 to 2.503 mm (0.09846 to 0.09854 in.)
      Mark 3 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
      Mark 4 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
      Mark 5 2.510 to 2.512 mm (0.09882 to 0.09890 in.)
  12. INSPECT CRANKSHAFT BEARING CAP SET BOLT 
    1. Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard Diameter

      10.8 to 11.0 mm (0.4252 to 0.4331 in.)

      Minimum Diameter

      10.7 mm (0.4213 in.)

      Measurement Point (Distance from the Seat)

      47 mm (1.85 in.)

      GTY457492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Point
      *b Distance from the Seat

      HINT: 

      • If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage.
      • If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.
  13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Push the check valve with a pin to check that it is not stuck.
      GTY459297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If the check valve is stuck, replace the No. 1 oil nozzle sub-assembly.

    2. Push the check valve with a pin to check if it moves smoothly.

      HINT: 

      If the check valve does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly.

    3. 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).
      GTY470207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

    4. 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).
      GTY461375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If air does not pass through (C), clean or replace the No. 1 oil nozzle sub-assembly.

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