Cylinder Block (W/O Dpf) Inspection

Check the oil orifice for damage or clogging.
If necessary, replace the cylinder block oil orifice.

Push the ball of the oil check valve with a wooden stick to check if it is stuck.

Text in Illustration

*1	Ball
	Push

Check the No. 1 oil nozzle for damage or clogging.
If necessary, replace the No. 1 oil nozzle sub-assembly.

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

Using a soft brush and solvent, thoroughly clean the cylinder block sub-assembly.

Using a precision straightedge and feeler gauge, measure the surface of the cylinder block that contacts the cylinder head for warpage.

Maximum warpage:

0.1 mm (0.00394 in.)

Visually check the cylinders for vertical scratches.
If deep scratches are present, rebore all 4 cylinders. If necessary, replace the cylinder block.

Inspect the cylinder bore diameter.

HINT:

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

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

   Standard Diameter:

   Item	Specified Condition
   STD Mark 1	92.00 to 92.01 mm (3.6220 to 3.6224 in.)
   STD Mark 2	92.01 to 92.02 mm (3.6224 to 3.6228 in.)
   STD Mark 3	92.02 to 92.03 mm (3.6228 to 3.6232 in.)
   O/S 0.50	92.50 to 92.53 mm (3.6417 to 3.6429 in.)

   Maximum Diameter:

   Item	Specified Condition
   STD	92.23 mm (3.6311 in.)
   O/S 0.50	92.73 mm (3.6508 in.)

   Text in Illustration

   *1	Axial Direction
   *2	Thrust Direction
   *3	Center
   	Front

   If the diameter is more than the maximum, rebore all 4 cylinders. If necessary, replace the cylinder block sub-assembly.
   If the wear is less than 0.2 mm (0.00787 in.), using a ridge reamer, grind the top of the cylinder.
   

   Text in Illustration

   *1	Ridge Reamer

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

Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

Using a micrometer, measure the piston diameter according to the following conditions: 1) measure at a right angle to the piston center line, and 2) measure at the indicated distance from the piston head.

Standard Distance:

65 mm (2.56 in.)

Standard Piston Diameter:

Item	Specified Condition
STD Mark 1	91.92 to 91.93 mm (3.6189 to 3.6193 in.)
STD Mark 2	91.93 to 91.94 mm (3.6193 to 3.6197 in.)
STD Mark 3	91.94 to 91.95 mm (3.6197 to 3.6201 in.)
O/S 0.50	92.42 to 92.45 mm (3.6386 to 3.6398 in.)

Standard Pin Hole Inside Diameter:

Item	Specified Condition
Mark 1	33.998 to 34.002 mm (1.3385 to 1.3387 in.)
Mark 2	34.002 to 34.006 mm (1.3387 to 1.3388 in.)
Mark 3	34.006 to 34.010 mm (1.3388 to 1.3390 in.)

Using a micrometer, measure the piston pin diameter.

Standard Piston Pin Diameter:

Item	Specified Condition
Mark A	33.996 to 34.000 mm (1.3384 to 1.3386 in.)
Mark B	34.000 to 34.004 mm (1.3386 to 1.3387 in.)
Mark C	34.004 to 34.008 mm (1.3387 to 1.3389 in.)

Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

Standard oil clearance:

-0.002 to 0.006 mm (0.0000787 to 0.000236 in.)

Inspect the piston pin fit.

1. At 80°C (176°F), check that the piston pin can be pushed into the piston pin hole with your thumb.
   If the pin can be installed at a lower temperature, replace the piston with pin sub-assembly.
   

Measure the cylinder bore diameter in the thrust direction.

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.07 to 0.09 mm (0.00276 to 0.00354 in.)

Maximum oil clearance:

0.16 mm (0.00639 in.)

HINT:

When the cylinder block is replaced, use a piston with the same number mark as the cylinder diameter marked on the new cylinder block.

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

Standard Groove Clearance:

Item	Specified Condition
No. 1 piston ring	0.060 to 0.100 mm (0.00236 to 0.00394 in.)
No. 2 piston ring	0.050 to 0.095 mm (0.00197 to 0.00374 in.)
Oil ring	0.030 to 0.075 mm (0.00118 to 0.00295 in.)

Maximum groove clearance:

0.20 mm (0.0787 in.)

Insert the piston ring into the cylinder bore.

Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

Standard End Gap:

Item	Specified Condition
No. 1 piston ring	0.27 to 0.39 mm (0.0106 to 0.0154 in.)
No. 2 piston ring	0.47 to 0.62 mm (0.0185 to 0.0244 in.)
Oil ring	0.20 to 0.40 mm (0.00787 to 0.0157 in.)

Maximum End Gap:

Item	Specified Condition
No. 1 piston ring	1.21 mm (0.0476 in.)
No. 2 piston ring	1.44 mm (0.0567 in.)
Oil ring	1.22 mm (0.0480 in.)

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

Standard Bush Inside Diameter:

Item	Specified Condition
Mark A	34.012 to 34.016 mm (1.3390 to 1.3392 in.)
Mark B	34.016 to 34.020 mm (1.3392 to 1.3393 in.)
Mark C	34.020 to 34.024 mm (1.3393 to 1.3395 in.)

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

Standard oil clearance:

0.012 to 0.020 mm (0.000472 to 0.000878 in.)

Maximum oil clearance:

0.03 mm (0.0118 in.)

Using a rod aligner and feeler gauge, check the connecting rod alignment.

1. Check if the connecting rod is bent.
   

   Maximum bend:

   0.03 mm (0.00118 in.) per 100 mm (3.94 in.)
   

   If the bend is more than the maximum, replace the connecting rod sub-assembly.
   




2. Check if the connecting rod is twisted.
   

   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 sub-assembly.
   

Using a vernier caliper, measure the diameter of the tension portion of the bolt.

Standard diameter:

8.5 to 8.6 mm (0.335 to 0.339 in.)

Minimum diameter:

8.3 mm (0.327 in.)

Inspect the 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:

   0.03 mm (0.00118 in.)
   

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

Inspect the main journals and crank pins.

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

   Standard Main Journal Diameter:

   Item	Specified Condition
   Mark 1	69.994 to 70.000 mm (2.7557 to 2.7559 in.)
   Mark 2	69.988 to 69.994 mm (2.7554 to 2.7557 in.)
   Mark 3	69.982 to 69.988 mm (2.7552 to 2.7554 in.)
   U/S 0.25	69.745 to 69.755 mm (2.7459 to 2.7463 in.)
   U/S 0.50	69.495 to 69.505 mm (2.7360 to 2.7364 in.)

   Standard Crank Pin Diameter:

   Item	Specified Condition
   Mark 1	58.994 to 59.000 mm (2.3226 to 2.3228 in.)
   Mark 2	58.988 to 58.994 mm (2.3224 to 2.3226 in.)
   Mark 3	58.982 to 58.988 mm (2.3221 to 2.3224 in.)

   If the diameter is not as specified, check the connecting rod oil clearance (HILUX_TGN26 RM00000147Q026X_01_0041.html) and crankshaft oil clearance (HILUX_TGN26 RM00000147Q026X_01_0043.html). If necessary, grind or 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 (0.000787 in.)
   

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

If necessary, grind and hone the main journals and/or crank pins.

1. Grind and hone the main journals and/or crank pins to the finished undersized diameter (refer to the procedures above).
   

2. Install new main journal and/or crank pin undersized bearings.
   

Using a vernier caliper, measure the diameter of the crankshaft bearing cap set bolt in the measuring area.

Standard diameter:

13.5 to 14.0 mm (0.531 to 0.551 in.)

Minimum diameter:

12.6 mm (0.496 in.)