Cylinder Block: Inspection: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT CONNECTING ROD THRUST CLEARANCE
1. Install the connecting rod cap . Refer to REASSEMBLY .
2. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  
  Fig 1: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.160 to 0.342 mm (0.0063 to 0.0135 in.)
  
  Maximum thrust clearance
  
  0.342 mm (0.0135 in.)
  
  If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.

INSPECT CONNECTING ROD OIL CLEARANCE

Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.
Lay a strip of Plastigage on the crank pin.

Fig 2: Laying Strip Of Plastigage On Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the front mark of the connecting rod cap is facing forward.

Fig 3: Identifying Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap . Refer to REASSEMBLY .
NOTE:
Do not turn the crankshaft.
Remove the 2 bolts and connecting rod cap . Refer to DISASSEMBLY .

Measure the Plastigage at its widest point.

Fig 4: Measuring Plastigage At Its Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.030 to 0.062 mm (0.0012 to 0.0024 in.)

Maximum oil clearance

0.07 mm (0.0028 in.)

If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

NOTE:

Completely remove the Plastigage after the measurement.

HINT:

If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each standard bearing thickness is indicated by a 1, 2, or 3 mark on its surface.

Standard Connecting Rod Large End Bore Diameter

Mark	Specified Condition
Mark 1	47.000 to 47.008 mm (1.8504 to 1.8507 in.)
Mark 2	47.009 to 47.016 mm (1.8507 to 1.8510 in.)
Mark 3	47.017 to 47.024 mm (1.8511 to 1.8513 in.)

Standard Connecting Rod Bearing Thickness

Mark	Specified Condition
Mark 1	1.489 to 1.493 mm (0.0586 to 0.0588 in.)
Mark 2	1.494 to 1.497 mm (0.0588 to 0.0589 in.)
Mark 3	1.498 to 1.501 mm (0.0590 to 0.0591 in.)

Standard Crankshaft Pin Diameter

Mark	Specified Condition
Mark 1,2,3	43.992 to 44.000 mm (1.7320 to 1.7323 in.)

INSPECT CYLINDER BLOCK FOR WARPAGE
1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.
  
  Fig 5: Measuring Warpage Of Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum warpage
  
  0.05 mm (0.0020 in.)
  
  If the warpage is greater than the maximum, replace the cylinder block.
INSPECT CYLINDER BORE
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both thrust and axial directions.
  
  Fig 6: View Of Cylinder Bore Inspection Procedure
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter
  
  80.500 to 80.513 mm (3.1693 to 3.1698 in.)
  
  Maximum diameter
  
  80.633 mm (3.1745 in.)
  
  If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.
INSPECT PISTON
1. Using a gasket scraper, remove the carbon from the top of the piston.
  
  Fig 7: Removing Carbon From Piston Top
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
  
  Fig 8: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brush and solvent, thoroughly clean the piston.
  
  Fig 9: Cleaning Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not use a wire brush.
4. Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 12.6 mm (0.4961 in.) from the piston head.
  
  Fig 10: Measuring Piston Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard piston diameter
  
  80.461 to 80.471 mm (3.1677 to 3.1681 in.)
  
  If the diameter is not as specified, replace the piston.
INSPECT PISTON OIL CLEARANCE
1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Standard oil clearance
  
  0.029 to 0.052 mm (0.0011 to 0.0020 in.)
  
  Maximum oil clearance
  
  0.09 mm (0.0035 in.)
  
  If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

INSPECT RING GROOVE CLEARANCE

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

Fig 11: Measuring Clearance Between Piston Ring And Wall Of Ring Groove

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Ring Groove Clearance

Item	Specified Condition
No. 1 Ring	0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2 Ring	0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil Ring	0.02 to 0.065 mm (0.0008 to 0.0026 in.)

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

INSPECT PISTON RING END GAP

Using a piston, push the piston ring a little beyond the bottom of the ring travel, 50 mm (1.97 in.) from the top of the cylinder block.

Fig 12: Identifying Piston Ring End Gap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a feeler gauge, measure the end gap.

Fig 13: Measuring End Gap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard End Gap

Item	Specified Condition
No. 1 Ring	0.2 to 0.3 mm (0.0079 to 0.0118 in.)
No. 2 Ring	0.3 to 0.5 mm (0.0118 to 0.0197 in.)
Oil Ring	0.1 to 0.4 mm (0.0039 to 0.0157 in.)

Maximum End Gap

Item	Specified Condition
No. 1 Ring	0.5 mm (0.0197 in.)
No. 2 Ring	0.7 mm (0.0276 in.)
Oil Ring	0.7 mm (0.0276 in.)

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, replace the cylinder block.

INSPECT PISTON PIN OIL CLEARANCE

Using a caliper gauge, measure the piston pin bore diameter.

Fig 14: Measuring Piston Pin Bore Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard piston pin bore diameter

20.006 to 20.015 mm (0.7876 to 0.7880 in.)

Item	Specified Condition
A	20.006 to 20.009 mm (0.7876 to 0.7878 in.)
B	20.010 to 20.012 mm (0.7878 to 0.7879 in.)
C	20.013 to 20.015 mm (0.7879 to 0.7880 in.)

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

Using a micrometer, measure the piston pin diameter.

Fig 15: Measuring Piston Pin Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard piston pin diameter

20.004 to 20.013 mm (0.7876 to 0.7879 in.)

Item	Specified Condition
A	20.004 to 20.007 mm (0.7876 to 0.7877 in.)
B	20.008 to 20.010 mm (0.7877 to 0.7878 in.)
C	20.011 to 20.013 mm (0.7878 to 0.7879 in.)

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

Using a caliper gauge, measure the connecting rod small end bore diameter.

Fig 16: Measuring Connecting Rod Small End Bore Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard connecting rod small end bore diameter

20.012 to 20.021 mm (0.7879 to 0.7882 in.)

Item	Specified Condition
A	20.012 to 20.015 mm (0.7879 to 0.7880 in.)
B	20.016 to 20.018 mm (0.7880 to 0.7881 in.)
C	20.019 to 20.021 mm (0.7881 to 0.7882 in.)

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

Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.

Fig 17: Identifying Connecting Rod Small Bore Diameter Mark
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

-0.001 to 0.005 mm (-0.00004 to 0.0002 in.)

Maximum oil clearance

0.010 mm (0.0004 in.)

If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance

0.014 mm (0.0006 in.)

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

INSPECT CONNECTING ROD BOLT
1. Using a vernier caliper, measure the tension portion diameter of the bolt.
  
  Fig 18: Identifying Connecting Rod Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter
  
  6.6 to 6.7 mm (0.2598 to 0.2638 in.)
  
  Minimum diameter
  
  6.4 mm (0.2520 in.)
  
  If the diameter is less than the minimum, replace the connecting rod bolt.
INSPECT CONNECTING ROD SUB-ASSEMBLY
1. Using a connecting rod aligner and a feeler gauge, check the connecting rod alignment.
  
  Fig 19: Checking Connecting Rod Alignment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Check for misalignment.
    Maximum misalignment
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the misalignment is greater than the maximum, replace the connecting rod.
  2. Check for twist.
    
    Fig 20: Checking For Connecting Rod Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Maximum twist
    
    0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
    
    If the twist is greater than the maximum, replace the connecting rod.

INSPECT CRANKSHAFT

Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.

Fig 21: Measuring Circle Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum circle runout

0.03 mm (0.0012 in.)

If the taper and distortion are greater than the maximum, replace the crankshaft.
Using a micrometer, measure the diameter of each main journal.

Fig 22: Identifying Diameter Of Main Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard diameter

47.988 to 48.000 mm (1.8893 to 1.8898 in.)

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

Check each main journal for taper and distortion as shown in the illustration.

Maximum taper and distortion

0.004 mm (0.0002 in.)

If the taper and distortion are greater than the maximum, replace the crankshaft.

Standard Diameter (Reference)

Mark	Specified Condition
0	47.999 to 48.000 mm (1.8897 to 1.8898 in.)
1	47.997 to 47.998 mm (1.8896 to 1.8897 in.)
2	47.995 to 47.996 mm (1.8896 to 1.8896 in.)
3	47.993 to 47.994 mm (1.8895 to 1.8895 in.)
4	47.991 to 47.992 mm (1.8894 to 1.8894 in.)
5	47.988 to 47.990 mm (1.8893 to 1.8894 in.)

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

Fig 23: Measuring Diameter Of Each Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard diameter

43.992 to 44.000 mm (1.7320 to 1.7323 in.)

If the diameter is not as specified, check the connecting rod oil clearance.
Inspect each crank pin for taper and distortion as shown in the illustration.
Maximum taper and distortion

0.004 mm (0.0002 in.)

If the taper and distortion are greater than the maximum, replace the crankshaft.

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Install the main bearing cap . Refer to REASSEMBLY .
2. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  
  Fig 24: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.04 to 0.14 mm (0.0016 to 0.0055 in.)
  
  Maximum thrust clearance
  
  0.18 mm (0.0071 in.)
  
  If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
  
  HINT:
  
  The thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 in.).

INSPECT CRANKSHAFT OIL CLEARANCE

Check the crank journal and bearing for pitting and scratches.
Install the crankshaft bearing . Refer to REASSEMBLY .
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.

Fig 25: Measuring Plastigage At Its Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Examine the front marks and numbers and install the bearing caps on the cylinder block.
HINT:

A number is marked on each main bearing cap to indicate the installation position.
Install the main bearing cap . Refer to REASSEMBLY .
NOTE:
Do not turn the crankshaft.
Remove the main bearing caps . Refer to DISASSEMBLY .

Measure the Plastigage at its widest point.

Fig 26: Measuring Plastigage Widest Point

Standard oil clearance

0.016 to 0.039 mm (0.0006 to 0.0015 in.)

Maximum oil clearance

0.050 mm (0.0020 in.)

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

NOTE:

Remove the Plastigage completely after the measurement.

HINT:

If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number according to the chart below. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3")

Cylinder block + Crankshaft	0 to 2	3 to 5	6 to 8	9 to 11
Bearing to be used	"1"	"2"	"3"	"4"

Standard Cylinder Block Journal Bore Diameter

Mark	Specified Condition
0	52.000 to 52.003 mm (2.0472 to 2.0474 in.)
1	52.003 to 52.005 mm (2.04736 to 2.04744 in.)
2	52.005 to 52.007 mm (2.0474 to 2.0475 in.)
3	52.007 to 52.010 mm (2.0475 to 2.0476 in.)
4	52.010 to 52.012 mm (2.0476 to 2.0477 in.)
5	52.012 to 52.014 mm (2.0477 to 2.0478 in.)
6	52.014 to 52.016 mm (2.0478 to 2.0479 in.)

Standard Crankshaft Journal Diameter

Mark	Specified Condition
0	47.999 to 48.000 mm (1.8897 to 1.8898 in.)
1	47.997 to 47.998 mm (1.8896 to 1.8897 in.)
2	47.995 to 47.996 mm (1.88956 to 1.88960 in.)
3	47.993 to 47.994 mm (1.8895 to 1.8895 in.)
4	47.991 to 47.992 mm (1.8894 to 1.8894 in.)
5	47.988 to 47.990 mm (1.8893 to 1.8894 in.)

Standard Bearing Center Wall Thickness

Mark	Specified Condition
1	1.994 to 1.997 mm (0.0785 to 0.0786 in.)
2	1.998 to 2.000 mm (0.07866 to 0.07874 in.)
3	2.001 to 2.003 mm (0.0788 to 0.0789 in.)
4	2.004 to 2.006 mm (0.0789 to 0.0790 in.)

INSPECT CYLINDER HEAD SET BOLT
1. Using a vernier caliper, measure the tension portion diameter of the bolts.
  
  Fig 27: Identifying Cylinder Head Set Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard bolt length
  
  84.3 to 85.7 mm (3.3189 to 3.3740 in.)
  
  Maximum bolt length
  
  86.7 mm (3.4134 in.)
  
  If the bolt length is greater than the maximum, replace the bolt.
2. Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.
  Standard outside diameter
  
  9.77 to 9.96 mm (0.3846 to 0.3921 in.)
  
  Minimum outside diameter
  
  9.1 mm (0.3583 in.)
  
  HINT:
  
  Using a straightedge, visually check for thinner areas of the threaded part of the crankshaft bearing cap bolt.
  
  If the diameter is less than the minimum, replace the bolt.
INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Check the oil nozzles for damage or clogging.
  HINT:
  
  If there is damage or clogging, replace the oil nozzle.