Engine Unit: Inspection: Inspection

1. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Using a soft brush and solvent, thoroughly clean the cylinder block.
   NOTE:

   If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.

1. Using a precision straightedge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.

   Maximum warpage

   0.07 mm (0.0028 in.)

   If the warpage is greater than the maximum, replace the cylinder block.

If deep scratches are present, replace the cylinder block.

HINT: 

There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.

If deep scratches are present, replace the cylinder block.

Fig 5: Measuring Cylinder Bore Diameter At Positions A And B In Thrust And Axial Directions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Reaming Cylinder Ridge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

   Standard diameter

   Number Mark	Specified Condition
   Mark 1	91.000 to 91.008 mm (3.5827 to 3.5830 in.)
   Mark 2	91.008 to 91.021 mm (3.5830 to 3.5835 in.)
   Mark 3	91.021 to 91.029 mm (3.5835 to 3.5838 in.)

   Maximum diameter

   91.149 mm (3.5885 in.)

   If the average of the diameter is greater than the maximum, replace the cylinder block.

   HINT: 

   If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

1. Using a gasket scraper, remove the carbon from the piston top.
Fig 8: Cleaning Piston Ring Grooves
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
Fig 9: Cleaning Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:

Do not use a wire brush.

3. Using solvent and a brush, thoroughly clean the piston.

HINT: 

There are 3 standard diameter sizes, marked "1", "2" and "3". The mark is stamped on the piston top.

1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 28.1 mm (1.106 in.) from the piston head.

   Piston diameter

   Number Mark	Specified Condition
   Mark 1	90.910 to 90.920 mm (3.5791 to 3.5795 in.)
   Mark 2	90.920 to 90.928 mm (3.5795 to 3.5798 in.)
   Mark 3	90.928 to 90.938 mm (3.5798 to 3.5802 in.)

2. Measure the cylinder bore diameter in the thrust directions.
3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

   Standard oil clearance

   0.080 to 0.101 mm (0.0031 to 0.0040 in.)

   Maximum oil clearance

   0.124 mm (0.0049 in.)

   If the oil clearance is greater than the maximum, replace all 8 pistons. If necessary, replace the cylinder block.

   Fig 11: Measuring Cylinder Bore Diameter In Thrust Directions

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Use a new cylinder block 

   • Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
   • The shape of the piston varies for the LH and RH banks. The LH piston is marked with a "3L" and the RH piston is marked with a "3R".

1. At 60°C (140°F), check that the piston pin can be pushed into the piston pin hole with your thumb.

Piston pin diameter

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

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

   Ring groove clearance

   Piston Ring	Specified Condition
   No. 1	0.030 to 0.080 mm (0.0012 to 0.0031 in.)
   No. 2	0.020 to 0.060 mm (0.0008 to 0.0024 in.)

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

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 105 mm (4.13 in.) from the top of the cylinder block.
Fig 16: Measuring End Gap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the end gap.

   Standard end gap

   End Gap	Specified Condition
   No. 1 piston ring	0.300 to 0.400 mm (0.0118 to 0.0157 in.)
   No. 2 piston ring	0.400 to 0.500 mm (0.0157 to 0.0197 in.)
   Oil ring (Side rail)	0.150 to 0.500 mm (0.0059 to 0.0197 in.)

   Maximum end gap

   End Gap	Specified Condition
   No. 1 piston ring	1.10 mm (0.0433 in.)
   No. 2 piston ring	1.20 mm (0.0472 in.)
   Oil ring (Side rail)	1.10 mm (0.0433 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.

1. Check if the connecting rod is bent.

   Maximum bend

   0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

   If the bend is greater than the maximum, replace the connecting rod.

Fig 18: Checking Connecting Rod Twist
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check if the connecting rod is twisted.

   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 sub-assembly.

1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

   Bushing inside diameter

   22.005 to 22.014 mm (0.8663 to 0.8667 in.)

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

2. Subtract the piston pin diameter measurement from the bush inside diameter measurement.

   Standard oil clearance

   0.005 to 0.011 mm (0.0002 to 0.0004 in.)

   Maximum oil clearance

   0.05 mm (0.0020 in.)

   If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and piston pin with a new piston and pin set.

Standard diameter

7.200 to 7.300 mm (0.2835 to 0.2874 in.)

Maximum diameter

7.00 mm (0.2756 in.)

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

Standard diameter

7.500 to 7.600 mm (0.2953 to 0.2992 in.)

Maximum diameter

7.20 mm (0.2835 in.)

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

1. Place the crankshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.

   Maximum circle runout

   0.08 mm (0.0031 in.)

   If the circle runout is greater the maximum, replace the crankshaft.

1. Using a micrometer, measure the diameter of each main journal and crank pin.

   Main journal diameter

   66.988 to 67.000 mm (2.6373 to 2.6378 in.)

   Crank pin diameter

   51.982 to 52.000 mm (2.0465 to 2.0472 in.)

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

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

   Maximum taper and out of round

   0.02 mm (0.0008 in.)

   If the taper and out of round is greater than the maximum, replace the crankshaft.