Cylinder Block Inspection

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

Maximum warpage:

0.05 mm (0.00197 in.)

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

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

Standard diameter:

94.990 to 95.003 mm (3.7398 to 3.7403 in.)

Maximum difference in diameter:

0.2 mm (0.00787 in.)

Measurement position:

70 mm (2.76 in.)

Text in Illustration

*1	Thrust Direction
*2	Axial Direction
*3	Measurement Position
	Front

Inspect the cylinder ridge.

Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified.

Distance:

13.8 mm (0.543 in.)

Standard diameter:

94.940 to 94.966 mm (3.7378 to 3.7384 in.)

Measure the cylinder bore diameter in the thrust direction.

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

Standard oil clearance:

0.024 to 0.063 mm (0.000945 to 0.00248 in.)

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	0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 compression ring	0.020 to 0.060 mm (0.000787 to 0.00236 in.)
Oil ring	0.020 to 0.060 mm (0.000787 to 0.00236 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	0.26 to 0.31 mm (0.0102 to 0.0122 in.)
No. 2 compression ring	0.59 to 0.71 mm (0.0232 to 0.0280 in.)
Oil ring	0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Maximum End Gap:

Item	Specified Condition
No. 1 compression ring	0.90 mm (0.0354 in.)
No. 2 compression ring	1.36 mm (0.0535 in.)
Oil ring	0.75 mm (0.0295 in.)

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

Standard Piston Pin Hole Inside Diameter:

Item	Specified Condition
A	22.001 to 22.004 mm (0.86618 to 0.86630 in.)
B	22.005 to 22.007 mm (0.86634 to 0.86642 in.)
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.)
b	5 mm (0.197 in.)

Standard Piston Pin Diameter:

Item	Specified Condition
A	21.997 to 22.000 mm (0.86602 to 0.86614 in.)
B	22.001 to 22.003 mm (0.86618 to 0.86626 in.)
C	22.004 to 22.006 mm (0.86630 to 0.86638 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:

0.010 mm (0.000394 in.)

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

Standard Bush Inside Diameter:

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

0.025 mm (0.000984 in.)

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

1. Check for bend.
   

   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 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.
   

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.

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

   Standard Journal Diameter:

   Item	Specified Condition
   No. 3 journal	59.981 to 59.994 mm (2.361 to 2.362 in.)
   Except No. 3 journal	59.987 to 60.000 mm (2.3617 to 2.3622 in.)

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

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

   Maximum taper and out-of-round:

   0.005 mm (0.000197 in.)
   

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

Inspect the crank pins.

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

   Standard diameter:

   52.989 to 53.002 mm (2.086 to 2.087 in.)
   

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

2. Check each crank pin for taper and out-of-round as shown in the illustration.
   

   Maximum taper and out-of-round:

   0.003 mm (0.000118 in.)
   

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

Clean each main journal and bearing.

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

Install the crankshaft bearings and upper crankshaft thrust washers.

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Install the 5 crankshaft bearing caps with the 10 bolts (HILUX_TGN26 RM00000125B044X_02_0060.html).

NOTICE:

Do not turn the crankshaft.

Remove the 10 bolts and 5 crankshaft bearing caps (HILUX_TGN26 RM00000125A04MX_04_0135.html).

Measure the Plastigage at its widest point.

Standard Oil Clearance:

Item	Specified Condition
No. 3 journal	0.030 to 0.055 mm (0.00118 to 0.00217 in.)
Other journals	0.024 to 0.049 mm (0.000945 to 0.00193 in.)

Maximum oil clearance:

0.10 mm (0.00394 in.)

Standard Cylinder Block Main Journal Bore Diameter:

Item	Specified Condition
Mark 1	64.004 to 64.010 mm (2.51984 to 2.52007 in.)
Mark 2	64.011 to 64.016 mm (2.52011 to 2.52031 in.)
Mark 3	64.017 to 64.022 mm (2.52035 to 2.52055 in.)

Standard Bearing Center Wall Thickness:

Item	Specified Condition
Mark 1	1.987 to 1.990 mm (0.07823 to 0.07835 in.)
Mark 2	1.991 to 1.993 mm (0.07839 to 0.07846 in.)
Mark 3	1.994 to 1.996 mm (0.07850 to 0.07858 in.)

Completely remove the Plastigage.

Inspect the diameter of the journals.

1. Using a micrometer, measure the diameter of the balance shaft main journals.
   

   Standard Main Journal Diameter:

   Item	Specified Condition
   A	37.969 to 37.985 mm (1.49 to 1.50 in.)
   B	37.449 to 37.465 mm (1.474 to 1.475 in.)

Inspect the diameter of the bearings.

1. Using a cylinder gauge, measure the inside diameter of the balance shaft bearings.
   

   Standard Bearing Inside Diameter:

   Item	Specified Condition
   A	38.025 to 38.045 mm (1.497 to 1.498 in.)
   B	37.525 to 37.545 mm (1.477 to 1.478 in.)

Inspect the oil clearance.

1. Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement.
   

   Standard Oil Clearance:

   Item	Specified Condition
   A	0.040 to 0.076 mm (0.00157 to 0.00299 in.)
   B	0.060 to 0.096 mm (0.00236 to 0.00378 in.)

   Maximum oil clearance:

   0.15 mm (0.00591 in.)
   

   If the oil clearance is more than the maximum, replace the cylinder block and balance shaft.
   

Inspect the diameter of the journals.

1. Using a micrometer, measure the diameter of the balance shaft main journals.
   

   Standard Main Journal Diameter:

   Item	Specified Condition
   A	37.969 to 37.985 mm (1.49 to 1.50 in.)
   B	37.449 to 37.465 mm (1.474 to 1.475 in.)

Inspect the diameter of the bearings.

1. Using a cylinder gauge, measure the inside diameter of the balance shaft bearings.
   

   Standard Bearing Inside Diameter:

   Item	Specified Condition
   A	38.025 to 38.045 mm (1.497 to 1.498 in.)
   B	37.525 to 37.545 mm (1.477 to 1.478 in.)

Inspect the oil clearance.

1. Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement.
   

   Standard Oil Clearance:

   Item	Specified Condition
   A	0.040 to 0.076 mm (0.00157 to 0.00299 in.)
   B	0.060 to 0.096 mm (0.00236 to 0.00378 in.)

   Maximum oil clearance:

   0.15 mm (0.00591 in.)
   

   If the oil clearance is more than the maximum, replace the cylinder block and balance shaft.
   

Push the check valve with a pin to check if it is stuck.

Text in Illustration

Push

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

Blow air into A. Check that air does not leak from B.

Text in Illustration

Air

Push the check valve while blowing air into A. Check that air passes through B.

Text in Illustration

	Air
	Push

Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.

Distance:

64 mm (2.52 in.)

Standard diameter:

10.76 to 10.97 mm (0.424 to 0.432 in.)

Minimum diameter:

10.66 mm (0.420 in.)

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.)