Cylinder Block: Inspection

WARNING: This page is about a different car, the 2003 Toyota RAV4, 2002 Toyota RAV4, and 2001 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

Clean cylinder block .
1. Remove the gasket material.
  Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block.
  Using a soft brush and solvent, thoroughly clean the cylinder block.
  
  Fig 1: Cleaning Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less.
Inspect cylinder block .
1. Inspect for flatness.
  Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
  1. Maximum warpage: 0.08 mm (0.0031 in.)
  If warpage is greater than maximum, replace the cylinder block.
2. Visually check the cylinder for vertical scratches.
  
  Fig 3: Checking For Vertical Scratches
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If deep scratches are present, replace the cylinder block.
3. Inspect the cylinder bore diameter.
  Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
  1. Standard diameter: 86.000 - 86.013 mm (3.3858 - 3.3863 in.)
  2. Maximum diameter: 86.013 mm (3.3863 in.)
  If the diameter is greater than maximum, replace the cylinder block.
  
  Fig 4: Measuring Cylinder Bore Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove cylinder ridge .
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

Fig 5: Removing Cylinder Ridge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect crankshaft bearing cap bolts .

Fig 6: Measuring Tension Portion Diameter Of Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using vernier calipers, measure the tension portion diameter of the bolt.
1. Standard diameter: 7.5 - 7.6 mm (0.2953 - 0.2992 in.)
2. Minimum diameter: 7.2 mm (0.284 in.)
If the diameter is less than minimum, replace the bolt.
Clean piston .
1. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 7: Displaying Piston Top
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
  
  Fig 8: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brush and solvent, thoroughly clean the piston.
  
  Fig 9: Cleaning Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not use a wire brush.
Inspect piston .
1. Inspect the piston oil clearance.
  1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.4 mm (1.1968 in.) from the piston head.
    1. Piston diameter: 85.927 - 85.937 mm (3.3829 - 3.3833 in.)
  2. Measure the cylinder bore diameter in the thrust directions (See step 2).
    
    Fig 10: Inspecting Piston Oil Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
    1. Standard oil clearance: 0.063 - 0.086 mm (0.0025 - 0.0034 in.)
    2. Maximum oil clearance: 0.10 mm (0.0039 in.)
    If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.
2. 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:
  
  Fig 11: Displaying Piston Ring Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 12: Ring Groove Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clearance is not as specified, replace the piston.
3. Inspect the piston ring end gap.
  1. Insert the piston ring into the cylinder bore.
  2. Using the 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.
    
    Fig 13: Inspecting Piston Ring End Gap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a feeler gauge, measure the end gap.
    
    Fig 14: Measuring End Gap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard end gap:
    
    Fig 15: Displaying Standard End Gap Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Maximum end gap:
    
    Fig 16: Displaying Maximum End Gap Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
4. Inspect the piston pin fit.
  
  Fig 17: Inspecting Piston Pin Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  At 80 - 90°C (176 - 194°F), you should be able to push the piston pin into the piston pin hole with your thumb.
Inspect connecting rod .
1. Using a rod aligner and a feeler gauge, check the connecting rod alignment.
  1. Check for out-of-alignment.
    1. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    If out-of-alignment is greater than maximum, replace the connecting rod assembly.
  2. Check for twist.
    1. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
    If twist is greater than maximum, replace the connecting rod assembly.
    
    Fig 19: Checking For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the piston pin oil clearance.
  1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
    1. Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 in.)
  2. Using a micrometer, measure the piston pin diameter.
    1. Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 in.)
  3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
    1. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.)
    2. Maximum oil clearance: 0.05 mm (0.0020 in.)
    If the oil clearance is greater than maximum, replace the bushing (See REPLACEMENT ). If necessary, replace the piston and piston pin as a set.
Inspect connecting rod bolts .

Fig 22: Inspecting Connecting Rod Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using vernier calipers, measure the tension portion diameter of the bolt.
1. Standard diameter: 7.2 - 7.3 mm (0.283 - 0.287 in.)
2. Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
Inspect crankshaft .
1. Inspect for circle runout.
  1. Place the crankshaft on V-blocks.
  2. Using a dial indicator, measure the circle runout, as shown in the illustration.
    1. Maximum circle runout: 0.03 mm (0.0012 in.)
  If the circle runout is greater than maximum, replace the crankshaft.
2. Inspect the main journals and crank pins.
  1. Using a micrometer, measure the diameter of each main journal and crank pin.
    Diameter:
    
    Fig 25: Displaying Diameter Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the diameter is not as specified, check the oil clearance (See DISASSEMBLY ). If necessary, replace the crankshaft.
  2. Check each main journal and crank pin for taper and out-of-round as shown.
    1. Maximum taper and out-of-round: 0.003 mm (0.0001 in.)
    If the taper and out-of-round is greater than maximum, replace the crankshaft.