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Cylinder Block: Inspection

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  1. Clean Cylinder Block 
    1. Remove the gasket material.

      Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

      Fig 1: Removing Gasket Material
      G02925608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the cylinder block.

      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, so always wash the cylinder block at a temperature of 45°C (133°F) or less.
  2. Inspect Cylinder Block 
    1. Inspect for flatness.

      Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

      Maximum Warpage:  0.05 mm (0.0020 in.)

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

      Fig 2: Measuring Surface Contacting Cylinder Head Gasket For Warpage
      G02925609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
      Fig 3: Checking Cylinder For Vertical Scratches
      G02925610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect the cylinder bore diameter.

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

      • Specified Diameter:  88.500-88.513 mm (3.4843-3.4847 in.)
      • Maximum Diameter:  88.633 mm (3.4894 in.)

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

      Fig 4: Measuring Cylinder Bore Diameter
      G02925611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove Cylinder Ridge 

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

    Fig 5: Grinding Top Of Cylinder Using Ridge Reamer
    G02925612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Inspect Crankshaft Bearing Cap Bolts 

    Using vernier calipers, measure the tension portion diameter of the bolt.

    • Standard Diameter:  7.5-7.6 mm (0.2953-0.2992 in.)
    • Minimum Diameter:  7.2 mm (0.284 in.)

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

    Fig 6: Measuring Tension Portion Diameter
    G02925613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Clean Piston 
    1. Using a gasket scraper, remove the carbon from the piston top.
      Fig 7: Removing Carbon From Piston Top
      G02925614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
      Fig 8: Cleaning Piston Ring Grooves
      G02925615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush and solvent, thoroughly clean the piston.
      NOTE: Do not use a wire brush.
      Fig 9: Cleaning Piston Using Brush & Solvent
      G02925616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Inspect Piston 
    1. Inspect the piston oil clearance.
      1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.4 mm (1.1967 in.) from the piston head.

        Piston Diameter:  88.439-88.449 mm (3.4818-3.4822 in.)

        Fig 10: Measuring Piston Diameter At Right Angles
        G02925617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Measure the cylinder bore diameter in the thrust directions. See step  2.
      3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
        • Standard Oil Clearance:  0.051-0.074 mm (0.0020-0.0029 in.)
        • Maximum Oil Clearance:  0.10 mm (0.0039 in.)

        If the oil clearance is greater than the maximum, replace all the 4 pistons. If necessary, replace the cylinder block.

    2. Inspect the piston ring groove clearance.

      Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. See RING GROOVE CLEARANCE REFERENCE  table.

      Ring Groove Clearance Reference

      No. 1 0.170-0.220 mm (0.0066-0.0086 in.)
      No. 2 0.170-0.210 mm (0.0066-0.0082 in.)
      Oil (Side rail) 0.210-0.290 mm (0.0082-0.0114 in.)

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

      Fig 11: Measuring Clearance Between Piston Ring & Wall Of Ring Groove
      G02925618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect the piston ring end gap.
      1. Insert the piston ring into the cylinder bore.
        Fig 12: Inserting Piston Ring Into Cylinder Bore
        G02925619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using the piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.
      3. Using a feeler gauge, measure the end gap. See STANDARD END GAP REFERENCE  and MAXIMUM END GAP REFERENCE  tables.
        Standard End Gap Reference

        No. 1 0.22-0.32 mm (0.0087-0.0126 in.)
        No. 2 0.50-0.60 mm (0.0197-0.0236 in.)
        Oil (Side Rail) 0.10-0.35 mm (0.0039-0.0138 in.)
        Maximum End Gap Reference

        No. 1 0.89 mm (0.0350 in.)
        No. 2 1.35 mm (0.0531 in.)
        Oil (Side Rail) 0.73 mm (0.0287 in.)

        If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.

        Fig 13: Measuring End Gap Of Piston Ring
        G02925620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Inspect the piston pin fit.

      At 80-90°C (176-194°F), you should be able to push the piston pin into the piston pin hole with your thumb.

      Fig 14: Inspecting Piston Pin Fit
      G02925621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Inspect Connecting Rod 
    1. Using a rod aligner and a feeler gauge, check the connecting rod alignment.
      1. Check for out-of-alignment.

        Maximum Out-Of-Alignment:  0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

        If out-of-alignment is greater than the maximum, replace the connecting rod assembly.

        Fig 15: Checking For Out-Of-Alignment
        G02925622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check for twist.

        Maximum Twist:  0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

        If twist is greater than the maximum, replace the connecting rod assembly.

        Fig 16: Checking For Twist
        G02925623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect the piston pin oil clearance.
      1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

        Bushing Inside Diameter:  22.005-22.014 mm (0.8663-0.8667 in.)

        Fig 17: Measuring Inside Diameter
        G02925624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using a micrometer, measure the piston pin diameter.

        Piston Pin Diameter:  21.997-22.006 mm (0.8660-0.8664 in.)

        Fig 18: Measuring Piston Pin Diameter
        G02925625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
        • Standard Oil Clearance:  0.005-0.011 mm (0.0002-0.0004 in.)
        • Maximum Oil Clearance:  0.05 mm (0.0020 in.)

        If the oil clearance is greater than the maximum, replace the bushing. See REPLACEMENT  . If necessary, replace the piston and piston pin as a set.

  8. Inspect Connecting Rod Bolts 

    Using vernier calipers, measure the tension portion diameter of the bolt.

    • Standard Diameter:  7.2-7.3 mm (0.283-0.287 in.)
    • Minimum Diameter:  7.0 mm (0.275 in.)

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

    Fig 19: Measuring Tension Portion Diameter
    G02925626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Inspect Crankshaft 
    1. Inspect for circle runout.
      1. Place the crankshaft on V-blocks.
      2. Using a dial indicator, measure the circle runout, as shown in Fig 20.

        Maximum Circle Runout:  0.03 mm (0.0012 in.)

        Fig 20: Measuring Circle Runout Crankshaft
        G02925627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Inspect the main journals and crank pins.
      1. Using a micrometer, measure the diameter of each main journal and crank pin. See DIAMETER REFERENCE  table.
        Diameter Reference

        Main Journal 54.988-55.000 mm (2.1649-2.1654 in.)
        Crank Pin 47.990-48.000 mm (1.8894-1.8898 in.)

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

      2. Check each main journal and crank pin for taper and out-of-round as shown in Fig 21.

        Maximum Taper & Out-Of-Round:  0.003 mm (0.0001 in.)

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

      Fig 21: Checking Each Journal & Crank Pin
      G02925628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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