Cylinder Block Inspection

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.

NOTICE:

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.

Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head gaskets.

Maximum warpage:

0.05 mm (0.00197 in.)

Visually check the cylinder for vertical scratches.
If necessary, replace the cylinder block.

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

Standard diameter:

94.000 to 94.012 mm (3.7008 to 3.7013 in.)

Maximum diameter:

94.132 mm (3.7060 in.)

Text in Illustration

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

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

Standard Ring Groove Clearance:

Item	Specified Condition
No. 1 compression ring	0.02 to 0.07 mm (0.000787 to 0.00276 in.)
No. 2 compression ring	0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Oil ring	0.07 to 0.15 mm (0.00276 to 0.00590 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, 110 mm (4.33 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

Standard End Gap:

Item	Specified Condition
No. 1 compression ring	0.22 to 0.32 mm (0.00866 to 0.0126 in.)
No. 2 compression ring	0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Oil ring (Side rail)	0.10 to 0.40 mm (0.00394 to 0.0157 in.)

Maximum End Gap:

Item	Specified Condition
No. 1 compression ring	1.0 mm (0.0394 in.)
No. 2 compression ring	1.1 mm (0.0433 in.)
Oil ring (Side rail)	1.0 mm (0.0394 in.)

Clean the piston.

1. Using a gasket scraper, remove the carbon from the piston top.
   

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

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

   NOTICE:

   Do not use a wire brush.

Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.09 in.) from the piston head.

Standard piston diameter:

93.910 to 93.920 mm (3.697 to 3.698 in.)

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

Standard oil clearance:

0.080 to 0.102 mm (0.00315 to 0.00401 in.)

Maximum oil clearance:

0.13 mm (0.00512 in.)

Check each mark on the piston and connecting rod.

Using a caliper gauge, measure the inside diameter of the piston pin hole.

Standard Piston Pin Hole Inside Diameter:

Item	Specified Condition
Mark A	22.001 to 22.004 mm (0.86618 to 0.86630 in.)
Mark B	22.005 to 22.007 mm (0.86634 to 0.86642 in.)
Mark C	22.008 to 22.010 mm (0.86645 to 0.86653 in.)

Using a micrometer, measure the piston pin diameter.

Measurement Position:

Measurement Position	Piston Pin Position
a	28 mm (1.10 in.) from edge
b	5 mm (0.197 in.) from edge

Standard Piston Pin Diameter:

Item	Specified Condition
Mark A	21.997 to 22.000 mm (0.86602 to 0.86614 in.)
Mark B	22.001 to 22.003 mm (0.86618 to 0.86626 in.)
Mark C	22.004 to 22.006 mm (0.86630 to 0.86642 in.)

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

Standard Bush Inside Diameter:

Item	Specified Condition
Mark A	22.005 to 22.008 mm (0.86634 to 0.86645 in.)
Mark B	22.009 to 22.011 mm (0.86649 to 0.86657 in.)
Mark C	22.012 to 22.014 mm (0.86661 to 0.86669 in.)

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

Standard oil clearance:

0.001 to 0.007 mm (0.0000394 to 0.000276 in.)

Maximum oil clearance:

0.040 mm (0.00157 in.)

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

Standard oil clearance:

0.005 to 0.011 mm (0.000197 to 0.000433 in.)

Maximum oil clearance:

0.050 mm (0.00197 in.)

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

1. Check for bend.
   

   Maximum bend:

   0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
   

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




2. Check for twist.
   

   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 dial indicator, measure the runout at the center journal.

Maximum circle runout:

0.06 mm (0.00236 in.)

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

Standard diameter:

71.988 to 72.000 mm (2.834 to 2.835 in.)

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

Maximum taper and out-of-round:

0.02 mm (0.000787 in.)

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

Standard diameter:

55.992 to 56.000 mm (2.204 to 2.205 in.)

Check each 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.)

Install the crankshaft bearings (HILUX_TGN26 RM000002BK603CX_01_0011.html).

Install the upper crankshaft thrust washers.

Clean each crankshaft journal and bearing.

Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Install the crankshaft bearing cap (HILUX_TGN26 RM000002BK603CX_01_0012.html).

NOTICE:

Do not turn the crankshaft.

Remove the crankshaft bearing cap.

Measure the Plastigage at its widest point.

Standard oil clearance:

0.018 to 0.030 mm (0.000709 to 0.00118 in.)

Maximum clearance:

0.046 mm (0.00181 in.)

If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

New Bearing:

Item	Specified Condition
Cylinder block main journal bore diameter (A) + Crankshaft main journal diameter (B)	0 to 5	6 to 11	12 to 17	18 to 23	24 to 28
Use bearing	1	2	3	4	5

Cylinder Block Main Journal Bore Diameter (A):

Item	Specified Condition
Mark 00	77.000 mm (3.03149 in.)
Mark 01	77.001 mm (3.03152 in.)
Mark 02	77.002 mm (3.03156 in.)
Mark 03	77.003 mm (3.03160 in.)
Mark 04	77.004 mm (3.03164 in.)
Mark 05	77.005 mm (3.03168 in.)
Mark 06	77.006 mm (3.03172 in.)
Mark 07	77.007 mm (3.03176 in.)
Mark 08	77.008 mm (3.03180 in.)
Mark 09	77.009 mm (3.03184 in.)
Mark 10	77.010 mm (3.03188 in.)
Mark 11	77.011 mm (3.03192 in.)
Mark 12	77.012 mm (3.03196 in.)
Mark 13	77.013 mm (3.03200 in.)
Mark 14	77.014 mm (3.03204 in.)
Mark 15	77.015 mm (3.03208 in.)
Mark 16	77.016 mm (3.03211 in.)

Crankshaft Main Journal Diameter (B):

Item	Specified Condition
Mark 00	71.999 to 72.000 mm (2.83460 to 2.83464 in.)
Mark 01	71.998 to 71.999 mm (2.83456 to 2.83460 in.)
Mark 02	71.997 to 71.998 mm (2.83452 to 2.83456 in.)
Mark 03	71.996 to 71.997 mm (2.83448 to 2.83452 in.)
Mark 04	71.995 to 71.996 mm (2.83440 to 2.83448 in.)
Mark 05	71.994 to 71.995 mm (2.83440 to 2.83444 in.)
Mark 06	71.993 to 71.994 mm (2.83436 to 2.83440 in.)
Mark 07	71.992 to 71.993 mm (2.83432 to 2.83436 in.)
Mark 08	71.991 to 71.992 mm (2.83428 to 2.83432 in.)
Mark 09	71.990 to 71.991 mm (2.83424 to 2.83428 in.)
Mark 10	71.989 to 71.990 mm (2.83420 to 2.83424 in.)
Mark 11	71.988 to 71.989 mm (2.83416 to 2.83420 in.)

Standard Bearing Center Wall Thickness:

Item	Specified Condition
Mark 1	2.488 to 2.491 mm (0.0980 to 0.0981 in.)
Mark 2	2.491 to 2.494 mm (0.0981 to 0.0982 in.)
Mark 3	2.494 to 2.497 mm (0.0982 to 0.0983 in.)
Mark 4	2.497 to 2.500 mm (0.0983 to 0.0984 in.)
Mark 5	2.500 to 2.503 mm (0.0984 to 0.0985 in.)

Completely remove the Plastigage.

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

Standard diameter:

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum diameter:

7.0 mm (0.276 in.)

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

Standard diameter:

10.0 to 10.2 mm (0.393 to 0.402 in.)

Push the check valve with a pin to check if it is stuck. If stuck, replace the No. 1 oil nozzle sub-assembly.

Push the check valve with a pin to check if it moves smoothly.
If it does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly.

While covering A, blow air into B. Check that air does not leak through C. Perform the check again while covering B and blowing air into A.
If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

Push the check valve while covering A, and blow air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and blowing air into A.
If air does not pass through C, clean or replace the No. 1 oil nozzle sub-assembly.