Inspection [08/2013 - ]: Procedure

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

INSPECT CYLINDER BLOCK FOR WARPAGE

Using a straightedge and feeler gauge, check the surface which contacts the cylinder head gasket for warpage.

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Maximum Warpage

0.05 mm (0.00197 in.)

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

INSPECT CYLINDER BORE

Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both the thrust and axial directions.

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*a	Thrust Direction
*b	Axial Direction
	Front

Reference Diameter (New Parts)

80.500 to 80.513 mm (3.169 to 3.170 in.)

Maximum Diameter

80.633 mm (3.175 in.)

Measurement Position

Measurement Position	Cylinder Bore Position
A	10 mm (0.394 in.) from top edge
B	50 mm (1.97 in.) from top edge

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

INSPECT PISTON

Using a gasket scraper, scrape off any carbon on the piston top.

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Using a groove cleaning tool or broken piston ring, clean the piston ring grooves.

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Using a brush and solvent, thoroughly clean the piston.

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NOTE:

Do not use a wire brush.

Using a micrometer, measure the piston diameter at a position 10.3 mm (0.406 in.) from the bottom of the piston (refer to the illustration).

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Reference Piston Diameter (New Parts)

80.476 to 80.496 mm (3.168 to 3.169 in.)

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

INSPECT PISTON OIL CLEARANCE
1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Reference Oil Clearance (New Parts)
  
  0.004 to 0.037 mm (0.000157 to 0.00169 in.)
  
  Maximum Oil Clearance
  
  0.08 mm (0.00315 in.)
  
  If the piston oil clearance is more than the maximum, replace all the pistons with piston pins. If necessary, replace the cylinder block sub-assembly.

INSPECT RING GROOVE CLEARANCE

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

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Standard Ring Groove Clearance

Item	Specified Condition
No. 1 Compression Ring	0.02 to 0.07 mm (0.000787 to 0.00276 in.)
No. 2 Compression Ring	0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Oil Ring (2-piece Type)	0.02 to 0.065 mm (0.000787 to 0.00256 in.)
Oil Ring (3-piece Type)	0.07 to 0.13 mm (0.00276 to 0.00512 in.)

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

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 sub-assembly.

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Using a feeler gauge, measure the end gap.

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Standard End Gap

Item	Specified Condition
No. 1 Compression Ring	0.20 to 0.30 mm (0.00787 to 0.0118 in.)
No. 2 Compression Ring	0.30 to 0.50 mm (0.0118 to 0.0197 in.)
Oil Ring (2-piece Type)	0.10 to 0.30 mm (0.00394 to 0.0157 in.)
Oil Ring (3-piece Type)	0.10 to 0.35 mm (0.00394 to 0.0138 in.)

Maximum End Gap

Item	Specified Condition
No. 1 Compression Ring	0.50 mm (0.0197 in.)
No. 2 Compression Ring	0.70 mm (0.0276 in.)
Oil Ring	0.60 mm (0.0276 in.)

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.

INSPECT PISTON PIN OIL CLEARANCE

HINT:

When replacing the piston sub-assembly (w/ pin) with a supply part, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.

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

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Standard Piston Pin Bore Diameter

Item	Specified Condition
Mark A	20.006 to 20.009 mm (0.78764 to 0.78775 in.)
Mark B	20.010 to 20.012 mm (0.78779 to 0.78787 in.)
Mark C	20.013 to 20.015 mm (0.78791 to 0.78799 in.)

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

Using a micrometer, measure the piston pin diameter.

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Standard Piston Pin Diameter

20.004 to 20.013 mm (0.78756 to 0.78791 in.)

Item	Specified Condition
Mark A	20.004 to 20.007 mm (0.78756 to 0.78768 in.)
Mark B	20.008 to 20.010 mm (0.78771 to 0.78779 in.)
Mark C	20.011 to 20.013 mm (0.78783 to 0.78791 in.)

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

Measurement Position

Measurement Position	Piston Pin Position
a	25 mm (0.984 in.) from side edge
b	5 mm (0.197 in.) from side edge

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

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Standard Connecting Rod Small End Bush Bore Diameter

20.012 to 20.021 mm (0.78787 to 0.78823 in.)

Item	Specified Condition
Mark A	20.012 to 20.015 mm (0.78787 to 0.78799 in.)
Mark B	20.016 to 20.018 mm (0.78803 to 0.78811 in.)
Mark C	20.019 to 20.021 mm (0.78815 to 0.78823 in.)

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

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

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*a	Upper Side
*b	Lower Side
*c	Front Mark
*d	Piston Pin Bore Diameter Mark
*e	Connecting Rod Small End Bush Bore Diameter Mark

Standard Oil Clearance

-0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)

Maximum Oil Clearance

0.008 mm (0.000394 in.)

If the oil clearance is more 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 bush bore diameter measurement.
Standard Oil Clearance

0.005 to 0.011 mm (0.000197 to 0.000433 in.)

Maximum Oil Clearance

0.014 mm (0.000551 in.)

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

INSPECT CONNECTING ROD SUB-ASSEMBLY

Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.

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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.

Check for twist.

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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.

INSPECT CRANKSHAFT

Inspect the runout.

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

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Maximum Circle Runout

0.03 mm (0.00118 in.)

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

Inspect the main journals.

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

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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 out-of-round as shown in the illustration.

Maximum Taper and Out-of-Round

0.004 mm (0.000157 in.)

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

Standard Diameter (Reference)

Mark	Specified Condition
0	47.999 to 48.000 mm (1.88972 to 1.88976 in.)
1	47.997 to 47.998 mm (1.88964 to 1.88968 in.)
2	47.995to 47.996 mm (1.88956 to 1.88960 in.)
3	47.993 to 47.994 mm (1.88948 to 1.88952 in.)
4	47.991 to 47.992 mm (1.88941 to 1.88945 in.)
5	47.988 to 47.990 mm (1.88929 to 1.88937 in.)

Inspect the crank pin.

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

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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 out-of-round.
Maximum Taper and Out-of-Round

0.004 mm (0.000157 in.)

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

INSPECT CRANKSHAFT OIL CLEARANCE

Check the crankshaft journals and crankshaft bearings for pitting and scratches.
Install the crankshaft bearings.
See step 4
Install the upper crankshaft thrust washers.
See step 5
Clean each main journal and crankshaft bearing.
Place the crankshaft on the cylinder block sub-assembly.

Lay a strip of Plastigage across each journal.

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*a	Plastigage

Examine the front marks and numbers and place 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.
Install the crankshaft bearing cap.
See step 6

NOTE:
Do not turn the crankshaft.
Remove the crankshaft bearing caps.
See step 9

Measure the Plastigage at its widest point.

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Plastigage

Number Mark

Standard Oil Clearance

0.016 to 0.039 mm (0.000630 to 0.00154 in.)

Maximum Oil Clearance

0.050 mm (0.00197 in.)

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

NOTE:

Remove the Plastigage completely after the measurement.

HINT:

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

Example:

Cylinder block "3" + Crankshaft "5" = Total number 8 (Use crankshaft bearing "3")

BEARING CHART

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

Standard Cylinder Block Journal Bore Diameter

Mark	Specified Condition
0	52.000 to 52.002 mm (2.04724 to 2.04732 in.)
1	52.003 to 52.004 mm (2.04736 to 2.0474840 in.)
2	52.005 to 52.006 mm (2.04744 to 2.04752 in.)
3	52.007 to 52.009 mm (2.04752 to 2.04759 in.)
4	52.010 to 52.011 mm (2.04763 to 2.04767 in.)
5	52.012 to 52.013 mm (2.04771 to 2.04775 in.)
6	52.014 to 52.016 mm (2.04779 to 2.04787 in.)

Standard Crankshaft Journal Diameter

Mark	Specified Condition
0	47.999 to 48.000 mm (1.88972 to 1.88976 in.)
1	47.997 to 47.998 mm (1.88964 to 1.88968 in.)
2	47.995 to 47.996 mm (1.88956 to 1.88961 in.)
3	47.993 to 47.994 mm (1.88948 to 1.88952 in.)
4	47.991 to 47.992 mm (1.88941 to 1.88945 in.)
5	47.988 to 47.990 mm (1.88929 to 1.88937 in.)

Standard Bearing Center Wall Thickness

Mark	Specified Condition
1	1.994 to 1.997 mm (0.07850 to 0.07862 in.)
2	1.998 to 2.000 mm (0.07866 to 0.07874 in.)
3	2.001 to 2.003 mm (0.07878 to 0.07886 in.)
4	2.004 to 2.006 mm (0.07890 to 0.07898 in.)

INSPECT CRANKSHAFT BEARING CAP SET BOLT

Using a vernier caliper, measure the length of the crankshaft bearing cap set bolt from the seat to end.

*a	Measurement length

Standard Length

84.3 to 85.7 mm (3.32 to 3.37 in.)

Maximum Length

86.7 mm (3.41 in.)

HINT:

If the length is greater than the maximum, replace the crankshaft bearing cap set bolt with a new one. 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.

Using a vernier caliper, measure the diameter of the elongated thread at the measurement area.

Standard Diameter

9.77 to 9.96 mm (0.385 to 0.392 in.)

Minimum Diameter

9.1 mm (0.358 in.)

HINT:

If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt with a new one. 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.

*a	Measurement point

INSPECT CONNECTING ROD BOLT

Using a vernier caliper, measure the tension portion diameter of the connecting rod bolt.

*a	Measurement Area

Standard Diameter

6.6 to 6.7 mm (0.260 to 0.264 in.)

Minimum Diameter

6.4 mm (0.252 in.)

If the diameter is less than the minimum, replace the connecting rod bolt with a new one.

INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

Push the check valve with a pin to check if it is stuck.

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

Push the check valve with a pin to check if it moves smoothly.
If it does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly.

Apply air into (A). Check that air does not leak through (B).

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

Push the check valve with a pin while applying air into (A). Check that air passes through (B).

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