EM−67

ENGINE MECHANICAL − CYLINDER BLOCK

EM13I−04

INSPECTION
1. CLEAN CYLINDER BLOCK
Remove the gasket material.
(1) Using a gasket scraper, remove all the gasket mate-
rial from the top surface of the cylinder block.
(2) Using a soft brush and solvent, thoroughly clean the
cylinder block.

A09452

2. INSPECT CYLINDER BLOCK

(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder
block.

A09453

(b) Visually check the cylinder for vertical scratches.

If the deep scratches are found, replace the cylinder block.

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ENGINE MECHANICAL − CYLINDER BLOCK

(c) Inspect the cylinder bore diameter.

1 Thrust Using a cylinder gauge, measure the cylinder bore diame-
1 Direction
Front ter at the positions A, B and C in the thrust and axial direc-
2 Axial
2 Direction tions.
Standard diameter:
10 mm 82.200 − 82.213 mm (3.2362 − 3.2367 in.)
A (0.39 in.) Maximum diameter: 82.400 mm (3.2441 in.)
B If the diameter is greater than maximum, replace the cylinder
block.
C 10 mm
(0.39 in.)

A09455

Ridge Reamer (d) Remove the cylinder ridge.

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

A09456

3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.

A09459

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

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ENGINE MECHANICAL − CYLINDER BLOCK

(c) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.

A09461

4. INSPECT PISTON AND PISTON RING

(a) Inspect the piston oil clearance.
(1) Using a micrometer, measure the piston diameter at
a right angles to the piston pin center line, 14 mm
(0.55 n.) below the skirt bottom edge.
Piston diameter:
82.148 − 82.182 mm (3.2341 − 3.2355 in.)
14 mm (2) Measure the cylinder bore diameter in the thrust
A09465 directions. (See step 2)
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.018 − 0.065 mm (0.0007 − 0.0026 in.)
Maximum oil clearance: 0.14 mm (0.0055 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons. If necessary, replace the cylinder block.

HINT:
There are 3 sizes of the diameter of the piston boss hole and
that of the piston pin. Pistons are marked with ”A”, ”B” and ”C”
Front according to the size. The mark is stamped on the piston top.
NOTICE:
Do not change the combinations of the piston and piston
pin because no mark is stamped on the piston pin.
Mark
A, B or C A20444

(b) Inspect the piston pin clearance.

(1) Using a caliper gauge, measure the inside diameter
of the piston boss.
Piston boss hole diameter:
Mark A 31.009 − 31.013 mm (1.2208 − 1.2210 in.)
Mark B 31.013 − 31.017 mm (1.2210 − 1.2211 in.)
Mark C 31.017 − 31.021 mm (1.2211 − 1.2213 in.)

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ENGINE MECHANICAL − CYLINDER BLOCK

(2) Using a micrometer, measure the piston pin diame-

ter.
Piston pin diameter:
Mark A 31.000 − 31.004 mm (1.2205 − 1.2206 in.)
Mark B 31.004 − 31.008 mm (1.2206 − 1.2208 in.)
Mark C 31.008 − 31.012 mm (1.2208 − 1.2209 in.)
(3) Subtract the piston pin diameter measurement from
the piston boss hole diameter measurement.
A20442
Standard pin clearance:
0.005 − 0.013 mm (0.0002 − 0.0005 in.)
If the pin clearance is not as specified, replace the piston and
piston pin as a set.

(c) Inspect the piston pin fit.

At 60 C˚ (140 ˚F), you should be able to push the piston
pin into the piston pin hole with your thumb.

A09463

(d) 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.
Ring groove clearance:
No.1 0.08 − 0.12 mm (0.0031 − 0.0047 in.)
No.2 0.06 − 0.10 mm (0.0024 − 0.0039 in.)
Oil 0.03 − 0.07 mm (0.0012 − 0.0028 in.)
If the clearance is not as specified, replace the piston.
A09462

(e) Inspect the piston ring end gap.

(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, 110 mm (4.33 in.) from
the top of the cylinder block.

110 mm

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ENGINE MECHANICAL − CYLINDER BLOCK

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

Standard end gap:
No. 1 0.27− 0.43 mm (0.0106 − 0.0169 in.)
No. 2 0.39− 0.58 mm (0.0154 − 0.0228 in.)
Oil 0.20− 0.44 mm (0.0079 − 0.0173 in.)
Maximum end gap:
No. 1 0.82 mm (0.0323 in.)

EM7639
No. 2 1.00 mm (0.0394 in.)
Oil 0.90 mm (0.0354 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.

5. INSPECT CONNECTING ROD AND PISTON PIN

(a) Using a rod aligner and feeler gauge, check the connect-
ing 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 the out−of−alignment is greater than maximum, replace the
connecting rod assembly.
A08041

(2) Check for twist

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod
assembly.

A09467

(b) Inspect the piston pin oil clearance.

(1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
31.015 − 31.027 mm (1.2211 − 1.2215 in.)

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ENGINE MECHANICAL − CYLINDER BLOCK

(2) Using a micrometer, measure the piston pin diame-

ter.
Piston pin diameter:
31.000 − 31.012 mm (1.2205 − 1.2209 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.011 − 0.019 mm (0.0004 − 0.0007 in.)
EM0227 Maximum oil clearance: 0.025 mm (0.0010 in.)
If the oil clearance is greater than maximum, replace the con-
necting rod. If necessary, replace the piston and piston pin as
a set.

(c) Inspect the piston pin fit at normal room temperature.

Coat the piston pin with engine oil, and push it into the
connecting rod with your thumb.

A09468

(d) Inspect the connecting rod bolt.

20 mm (0.79 in.) Using vernier calipers, measure the tension portion diam-
eter.
Standard diameter:
8.2 − 8.3 mm (0.323 − 0.327 in.)
Minimum diameter: 8.0 mm (0.315 in.)
If the diameter is less than minimum, replace the connecting rod
bolt.
A09491

6. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.025 mm (0.0010 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
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ENGINE MECHANICAL − CYLINDER BLOCK

(b) Inspect the main journals and crank pins.

(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
56.992 − 57.010 mm (2.2438 − 2.2445 in.)
Crank pin diameter:
50.482 − 50.500 mm (1.9875 − 1.9882 in.)
If the diameter is not as specified, replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out−of−round as shown.
Maximum taper and out−of−round:
0.01 mm (0.0004 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.

A09470

7. INSPECT CYLINDER BLOCK OIL ORIFICE

Check the oil orifice for clogging.
If necessary, replace the oil orifice.

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1CD−FTV ENGINE SUP (RM856E)