Cylinder Block (W/ Glow Plug Controller) 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.

Inspect for warpage.

1. 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.)
   

   If the warpage is more than the maximum, replace the cylinder block sub-assembly.
   

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	96.00 to 96.01 mm (3.7795 to 3.7799 in.)
   STD Mark 2	96.01 to 96.02 mm (3.7799 to 3.7803 in.)
   STD Mark 3	96.02 to 96.03 mm (3.7803 to 3.7807 in.)
   O/S 0.50	96.50 to 96.53 mm (3.7992 to 3.8004 in.)
   O/S 0.75	96.75 to 96.78 mm (3.8090 to 3.8102 in.)
   O/S 1.00	97.00 to 97.03 mm (3.8189 to 3.8201 in.)

   Maximum Diameter:

   Item	Specified Condition
   STD	96.23 mm (3.7886 in.)
   O/S 0.50	96.73 mm (3.8083 in.)
   O/S 0.75	96.98 mm (3.8181 in.)
   O/S 1.00	97.23 mm (3.8279 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 (0.0078 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.

Distance:

63.5 mm (2.50 in.)

Standard Piston Diameter:

Item	Specified Condition
STD Mark 1	95.92 to 95.93 mm (3.7764 to 3.7768 in.)
STD Mark 2	95.93 to 95.94 mm (3.7768 to 3.7772 in.)
STD Mark 3	95.94 to 95.95 mm (3.7772 to 3.7776 in.)
O/S 0.50	96.42 to 96.45 mm (3.7960 to 3.7972 in.)
O/S 0.75	96.67 to 96.70 mm (3.8059 to 3.8070 in.)
O/S 1.00	96.92 to 96.95 mm (3.8157 to 3.8169 in.)

Standard Pin Hole Inside Diameter:

Item	Specified Condition
Mark A	34.011 to 34.015 mm (1.3390 to 1.3392 in.)
Mark B	34.015 to 34.019 mm (1.3392 to 1.3393 in.)
Mark C	34.019 to 34.023 mm (1.3393 to 1.3395 in.)

Using a micrometer, measure the piston pin diameter.

Standard Piston Pin Diameter:

Item	Specified Condition
Mark A	34.000 to 34.004 mm (1.3386 to 1.3387 in.)
Mark B	34.004 to 34.008 mm (1.3387 to 1.3389 in.)
Mark C	34.008 to 34.012 mm (1.3389 to 1.3391 in.)

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

Standard oil clearance:

0.007 to 0.015 mm (0.000276 to 0.000591 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:

0.14 mm (0.00551 in.)

HINT:

When the cylinder block is replaced, use a piston with the same number mark as the cylinder diameter marked on a 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	0.091 to 0.135 mm (0.00358 to 0.00531 in.)
No. 2 piston ring	0.090 to 0.135 mm (0.00354 to 0.00531 in.)
Oil ring	0.030 to 0.075 mm (0.00118 to 0.00295 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	0.55 to 0.70 mm (0.0217 to 0.0276 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	0.85 mm (0.0335 in.)
No. 2 piston ring	1.07 mm (0.0421 in.)
Oil ring	0.77 mm (0.0303 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 1.3394 in.)
Mark C	34.020 to 34.024 mm (1.3394 to 1.3395 in.)

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

Standard oil clearance:

0.008 to 0.016 mm (0.000315 to 0.000630 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.)

Using a cylinder gauge, measure the inside diameter of the balanceshaft bearing.

Standard Bearing Inside Diameter:

Item	Specified Condition
No. 1	42.000 to 42.020 mm (1.6535 to 1.6543 in.)
No. 2	41.000 to 41.020 mm (1.6142 to 1.6150 in.)
No. 3	32.000 to 32.020 mm (1.2598 to 1.2606 in.)

Using a micrometer, measure the outside diameter of the balanceshaft main journals.

Standard Main Journal Diameter:

Item	Specified Condition
No. 1	41.941 to 41.960 mm (1.6512 to 1.6520 in.)
No. 2	40.931 to 40.950 mm (1.6115 to 1.6122 in.)
No. 3	31.941 to 31.960 mm (1.2575 to 1.2583 in.)

Subtract the outside diameter of the balanceshaft main journal from the inside diameter of the balanceshaft bearing.

Standard Oil Clearance:

Item	Specified Condition
No. 1	0.040 to 0.079 mm (0.00157 to 0.00311 in.)
No. 2	0.050 to 0.089 mm (0.00197 to 0.00350 in.)
No. 3	0.040 to 0.079 mm (0.00157 to 0.00311 in.)

Maximum Oil Clearance:

Item	Specified Condition
No. 1	0.18 mm (0.00709 in.)
No. 2	0.19 mm (0.00748 in.)
No. 3	0.18 mm (0.00709 in.)

Using a cylinder gauge, measure the inside diameter of the balanceshaft bearing.

Standard Bearing Inside Diameter:

Item	Specified Condition
No. 1	42.000 to 42.020 mm (1.6535 to 1.6543 in.)
No. 2	41.000 to 41.020 mm (1.6142 to 1.6150 in.)
No. 3	32.000 to 32.020 mm (1.2598 to 1.2606 in.)

Using a micrometer, measure the outside diameter of the balanceshaft main journals.

Standard Main Journal Diameter:

Item	Specified Condition
No. 1	41.941 to 41.960 mm (1.6512 to 1.6520 in.)
No. 2	40.931 to 40.950 mm (1.6115 to 1.6122 in.)
No. 3	31.941 to 31.960 mm (1.2575 to 1.2583 in.)

Subtract the outside diameter of the balanceshaft main journal from the inside diameter of the balanceshaft bearing.

Standard Oil Clearance:

Item	Specified Condition
No. 1	0.040 to 0.079 mm (0.00157 to 0.00311 in.)
No. 2	0.050 to 0.089 mm (0.00197 to 0.00350 in.)
No. 3	0.040 to 0.079 mm (0.00157 to 0.00311 in.)

Maximum Oil Clearance:

Item	Specified Condition
No. 1	0.18 mm (0.00709 in.)
No. 2	0.19 mm (0.00748 in.)
No. 3	0.18 mm (0.00709 in.)

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:

   0.03 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 RM00000147Q02KX_01_0083.html) and crankshaft oil clearance (HILUX_TGN26 RM00000147Q02KX_01_0089.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.)