Inspection [10/2022 - ]: Procedure

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INSPECT CYLINDER BLOCK FOR WARPAGE

Using a precision 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

Perform a visual inspection to confirm that there are no scratches, damage, etc. on the cylinder wall surface.
If there are any scratches, damage, etc. on the cylinder wall surface, replace the cylinder block sub-assembly.

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

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*a	Thrust Direction
*b	Axial Direction
*c	10 mm (0.394 in.)
*d	Center
	Front of Engine

Reference Diameter (New Parts)

87.500 to 87.513 mm (3.44488 to 3.44539 in.)

Maximum Diameter

87.63 mm (3.44999 in.)

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

INSPECT PISTON

Using a gasket scraper, remove any carbon from the piston top.

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Using a groove cleaning tool or a broken 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 right angle to the piston center line where the distance from the bottom of the piston is as specified.

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Distance

11 mm (0.433 in.)

Reference Piston Diameter (New Parts)

87.466 to 87.496 mm (3.44354 to 3.44472 in.)

INSPECT PISTON OIL CLEARANCE
1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Reference Oil Clearance (New Parts)
  
  0.004 to 0.047 mm (0.000157 to 0.00185 in.)
  
  Maximum Oil Clearance
  
  0.068 mm (0.00268 in.)
2. If the piston oil clearance is more than the maximum, replace all the piston with pin sub-assembly. If necessary, replace the cylinder block sub-assembly.

INSPECT RING GROOVE CLEARANCE

Using a feeler gauge, measure the clearance between a new piston ring set 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 0.05 mm (0.000787 to 0.00197 in.)
No. 2 compression ring	0.02 to 0.07 mm (0.000787 to 0.00276 in.)
Oil ring	0.07 to 0.12 mm (0.00276 to 0.00472 in.)

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

INSPECT PISTON RING END GAP

Insert the piston ring into the cylinder bore.

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*a	Piston Ring
*b	70 mm

Using a piston, push in the piston ring a little beyond the bottom of the ring travel, 70 mm (2.76 in.) from the top of the cylinder block sub-assembly.

Using a feeler gauge, measure the end gap.

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Standard End Gap

Item	Specified Condition
No. 1 compression ring	0.200 to 0.225 mm (0.00787 to 0.00886 in.)
No. 2 compression ring	0.650 to 0.700 mm (0.0256 to 0.0276 in.)
Oil ring (Side Rail)	0.100 to 0.350 mm (0.00394 to 0.0138 in.)

Maximum End Gap

Item	Specified Condition
No. 1 compression ring	0.475 mm (0.0187 in.)
No. 2 compression ring	0.950 mm (0.0374 in.)
Oil ring (Side Rail)	0.600 mm (0.0236 in.)

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

INSPECT PISTON PIN OIL CLEARANCE

HINT:

When replacing the piston and piston pin with supply parts, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.

Confirm each mark on the piston, piston pin and connecting rod.

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*a	Front Mark	*b	Piston Pin Hole Inside Diameter Mark
*c	Connecting Rod Small End Bush Inside Diameter Mark	-	-

Using a caliper gauge, measure the inside diameter of the piston pin hole.

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Standard Piston Pin Hole Inside Diameter

Mark	Specified Condition
A	23.001 to 23.004 mm (0.90555 to 0.90567 in.)
B	23.005 to 23.007 mm (0.90571 to 0.90579 in.)
C	23.008 to 23.010 mm (0.90582 to 0.90590 in.)

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

Using a micrometer, measure the piston pin diameter.

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Standard Piston Pin Diameter

Mark	Specified Condition
A	22.997 to 23.000 mm (0.90539 to 0.90551 in.)
B	23.001 to 23.003 mm (0.90555 to 0.90563 in.)
C	23.004 to 23.006 mm (0.90567 to 0.90575 in.)

Measurement Position

Measurement Position	Piston Pin Position
a	5.0 mm (0.197 in.) from side edge
b	26.0 mm (1.02 in.) from side edge

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

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

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Standard Connecting Rod Small End Bush Inside Diameter

Mark	Specified Condition
A	23.005 to 23.008 mm (0.90571 to 0.90582 in.)
B	23.009 to 23.011 mm (0.90586 to 0.90594 in.)
C	23.012 to 23.014 mm (0.90598 to 0.90606 in.)

If the inside diameter is not as specified, replace the connecting rod sub-assembly.
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

0.015 mm (0.000591 in.)
If the oil clearance is more than the maximum, replace the piston with pin sub-assembly.
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

0.021 mm (0.000827 in.)
If the oil clearance is more than the maximum, replace the connecting rod sub-assembly or piston with pin sub-assembly.

INSPECT CONNECTING ROD

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 for runout.

Clean the crank journal.
Place the crankshaft on V-blocks.

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

Maximum Runout

0.03 mm (0.00118 in.)

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

Inspect the main journals.

Using a micrometer, measure the diameter of each main journal.
Standard Main Journal Diameter

53.988 to 54.000 mm (2.12551 to 2.12598 in.)
If the diameter is not as specified, check the crankshaft oil clearance. If necessary, replace the crankshaft.

Check each main journal for taper and out-of-round as shown in the illustration.

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Maximum Taper and Out-of-round

0.003 mm (0.000118 in.)

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

Inspect the crank pins.

Using a micrometer, measure the diameter of each crank pin.
Standard Crank Pin Diameter

50.992 to 51.000 mm (2.00756 to 2.00787 in.)
If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft.

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

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Maximum Taper and Out-of-round

0.003 mm (0.000118 in.)

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

INSPECT CRANKSHAFT OIL CLEARANCE

Install the crankshaft bearings.
See step 7
Place the crankshaft on the cylinder block sub-assembly.
Install the crankshaft thrust washer uppers.
See step 9

Lay a strip of Plastigage across each journal.

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*a	Plastigage

Install the crankshaft bearing caps.
See step 10
NOTE:
- Do not turn the crankshaft.
- Do not apply engine oil to the crankshaft bearing or crankshaft journal.
Remove the crankshaft bearing caps.
See step 6 [10/2022 - 11/2023], or see step 6 [11/2023 - ]

Measure the Plastigage at its widest point.

*a	Plastigage

Standard Oil Clearance

0.020 to 0.041 mm (0.000787 to 0.00161 in.)

Maximum Oil Clearance

0.041 mm (0.00161 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, calculate 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.

*a	Cylinder Block Number Mark (A)	*b	Crankshaft Number Mark (B)
*c	Diameter Mark	-	-

EXAMPLE

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

Select the crankshaft bearing marked "3".

Crankshaft Bearing Chart

(A) + (B)	Use Crankshaft Bearing
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	60.000 to 60.002 mm (2.36220 to 2.36228 in.)
1	60.003 to 60.004 mm (2.36232 to 2.36236 in.)
2	60.005 to 60.006 mm (2.36240 to 2.36244 in.)
3	60.007 to 60.009 mm (2.36248 to 2.36255 in.)
4	60.010 to 60.011 mm (2.36259 to 2.36263 in.)
5	60.012 to 60.013 mm (2.36267 to 2.36271 in.)
6	60.014 to 60.016 mm (2.36275 to 2.36283 in.)

Standard Crankshaft Main Journal Diameter (B)

Mark	Specified Condition
0	53.999 to 54.000 mm (2.12594 to 2.12598 in.)
1	53.997 to 53.998 mm (2.12586 to 2.12590 in.)
2	53.995 to 53.996 mm (2.12578 to 2.12582 in.)
3	53.993 to 53.994 mm (2.12570 to 2.12574 in.)
4	53.991 to 53.992 mm (2.12563 to 2.12567 in.)
5	53.988 to 53.990 mm (2.12551 to 2.12559 in.)

Standard Crankshaft Bearing Center Wall Thickness

Mark	Specified Condition
1	3.002 to 3.005 mm (0.11819 to 0.11831 in.)
2	3.006 to 3.008 mm (0.11835 to 0.11842 in.)
3	3.009 to 3.011 mm (0.11846 to 0.11854 in.)
4	3.012 to 3.014 mm (0.11858 to 0.11866 in.)

Perform the inspection for each journal.

INSPECT CRANKSHAFT BEARING CAP SET BOLT

for 112.2 mm crankshaft bearing cap set bolt:

Using a vernier caliper, measure the outer diameter at position (A) shown in the illustration.

*a	Measurement Area (B)
*b	5.0 mm (0.197 in.)
*c	10 mm (0.394 in.)
	Measurement Location (A)

Standard Diameter

10.73 to 10.97 mm (0.422 to 0.432 in.)

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 crankshaft bearing cap set bolt are damaged, replace the bolt with a new one.
Calculate the difference between the measurement at position (A) and position (B).
Minimum Diameter

The outer diameter difference is 0.30 mm (0.0118 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 crankshaft bearing cap set bolt with a new one.

INSPECT CONNECTING ROD BOLT

Using a vernier caliper, measure the outer diameter at position (A) shown in the illustration.

*a	Measurement Area (B)
*b	5.0 mm (0.197 in.)
*c	10 mm (0.394 in.)
	Measurement Location (A)

Standard Diameter

8.36 to 8.5 mm (0.329 to 0.335 in.)

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.
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.

INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

Blow air into the (A) side, and check that air passes through (B) easily.

Air

If the result is not as specified, replace the No. 1 oil nozzle sub-assembly.

INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY

Blow air into the (A) side, and check that air passes through (B) easily.

Air

If the result is not as specified, replace the No. 2 oil nozzle sub-assembly.