Cylinder Block Assembly: Testing and Inspection

1NR-FE ENGINE MECHANICAL: CYLINDER BLOCK: INSPECTION

1. INSPECT CRANKSHAFT

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

Maximum circle runout:

0.02 mm (0.000787 in.)

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

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

Standard diameter:

47.988 to 48.000 mm (1.88929 to 1.88976 in.)

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

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

Maximum taper and distortion:

0.003 mm (0.000118 in.)

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

Standard Diameter (Reference):

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

Standard diameter:

41.992 to 42.000 mm (1.6532 to 1.6535 in.)

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

(e) Inspect each crank pin for taper and distortion as shown in the illustration.

Maximum taper and distortion:

0.003 mm (0.000118 in.)

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

2. INSPECT CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.

Maximum warpage:

0.05 mm (0.00197 in.)

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

3. INSPECT CYLINDER BORE

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

Text in Illustration

Standard diameter:

72.500 to 72.513 mm (2.8543 to 2.8548 in.)

Maximum diameter:

72.513 mm (2.8548 in.)

If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.

4. INSPECT PISTON

(a) Using a gasket scraper, remove the carbon from the top of the piston.

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

NOTICE:
Do not use a wire brush.

(d) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 8.8 mm (0.346 in.) from the piston bottom.

Standard piston diameter:

72.435 to 72.445 mm (2.8518 to 2.8522 in.)

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

5. INSPECT PISTON OIL CLEARANCE

(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.055 to 0.078 mm (0.00217 to 0.00307 in.)

Maximum oil clearance:

0.108 mm (0.00425 in.)

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

6. INSPECT RING GROOVE CLEARANCE

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

Standard Ring Groove Clearance:

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

7. INSPECT PISTON RING END GAP

(a) 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.

(b) Using a feeler gauge, measure the end gap.

Standard End Gap:

Maximum End Gap:

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.

8. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Install the main bearing cap Reassembly.

(b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance:

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum thrust clearance:

0.28 mm (0.0110 in.)

If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

HINT
The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

9. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Install the connecting rod cap Reassembly.

(b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.1 to 0.5 mm (0.00394 to 0.0197 in.)

Maximum thrust clearance:

0.5 mm (0.0197 in.)

If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.

10. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Check the crank journal and bearing for pitting and scratches.

(b) Install the crankshaft bearing Reassembly.

(c) Place the crankshaft on the cylinder block.

Text in Illustration

(d) Lay a strip of Plastigage across each journal.

(e) 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.

(f) Install the main bearing cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(g) Remove the main bearing caps Disassembly.

(h) Measure the Plastigage at its widest point.

Text in Illustration

Standard oil clearance:

0.019 to 0.043 mm (0.000748 to 0.00169 in.)

Maximum oil clearance:

0.049 mm (0.00192 in.)

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

NOTICE:
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 "2", "3", "4" and "5" accordingly.
* EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "4")

Standard Cylinder Block Journal Bore Diameter:

Standard Crankshaft Journal Diameter:

Standard Bearing Center Wall Thickness:

11. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Clean the crank pin and bearing.

(b) Check the crank pin and bearing for pitting and scratches.

(c) Lay a strip of Plastigage across the crank pin.

Text in Illustration

(d) Check that the front mark of the connecting rod cap is facing forward.

Text in Illustration

(e) Install the connecting rod cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(f) Remove the 2 bolts and connecting rod cap Disassembly.

(g) Measure the Plastigage at its widest point.

Text in Illustration

Standard oil clearance:

0.020 to 0.052 mm (0.000787 to 0.002047 in.)

Maximum oil clearance:

0.058 mm (0.00228 in.)

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

NOTICE:
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 bearing's standard thickness is indicated by mark 1, 2, or 3 on its surface.

Standard Connecting Rod Large End Bore Diameter:

Standard Connecting Rod Bearing Thickness:

Standard Crankshaft Pin Diameter:

12. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

Text in Illustration

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 bolt.

13. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the length of the bolts.

Text in Illustration

Standard bolt length:

75.3 to 76.7 mm (2.965 to 3.020 in.)

Maximum bolt length:

77.2 mm (3.039 in.)

If the bolt length is greater than the maximum, replace the bolt.

(b) Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

Text in Illustration

Standard bolt diameter:

9.94 to 9.96 mm (0.3914 to 0.3921 in.)

Minimum bolt diameter:

9.6 mm (0.377 in.)

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

14. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Check the oil nozzles for damage or clogging.

HINT
If there is damage or clogging, replace the oil nozzle.