Page 4025 of 5135
A09491
20 mm (0.79 in.)
A56040
A56041
A09474
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−51
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
17. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter.
Standard diameter:
8.0 to 8.3 mm (0.315 to 0.327 in.)
If the diameter is less than minimum, replace the connecting rod
bolt.
18. INSPECT CRANKSHAFT
(a) Place the crankshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.025 mm (0.0010 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(c) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
56.992 to 57.010 mm (2.2438 to 2.2445 in.)
Crank pin diameter:
50.482 to 50.500 mm (1.9875 to 1.9882 in.)
If the diameter is not as specified, replace the crankshaft.
(d) Check each main journal and crank pin for taper and out−
of−round as illustrated.
Maximum taper and out−of−round:
0.01 mm (0.0004 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
19. INSPECT CYLINDER BLOCK OIL ORIFICE
(a) Check the oil orifice for clogging.
If necessary, replace the oil orifice.
20. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Clean each main journal and bearing.
Page 4026 of 5135
A56038
A56042
A56039Groove
A09512
Groove
A09499
Plastigage
14−52− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(b) Install the bearing on the cylinder block and bearing cap.
HINT:
Each upper bearing has an oil groove and oil hole and each low-
er bearing does not.
(1) Align the bearing claw with the claw groove of the
cylinder clock, then push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, then push in the 5 lower bear-
ings.
(c) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
(d) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(e) Place the crankshaft on the cylinder block.
(f) Lay a strip of Plastigage across each journal.
Page 4027 of 5135
A56043
A09497
A09500
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−53
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(g) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(h) Apply a light coat of engine oil to the threads and under
the heads of the main bearing cap bolts.
(i) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several steps.
Torque: 115 Nm (1,173 kgfcm, 85 ftlbf)
NOTICE:
Do not turn the crankshaft.
(j) Remove the bearing cap.
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.032 to 0.100 mm (0.0013 to 0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ing. If necessary, replace the crankshaft.
Page 4028 of 5135
A09688
No. 1No. 2
No. 3
No. 4
No. 5No. 1
No. 2No. 3
No. 4
No. 5
Mark
1, 2 or 3
Mark
0, 1 or 2Mark
1, 2, 3, 4 or 5
14−54− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(l) If using the standard bearing, replace it with one having
the same number. If the number of the bearing cannot be
determined, find the correct number of the bearing by ad-
ding together the numbers imprinted on the cylinder block
and crankshaft, then select the bearing with the same
number as the total. There are 5 sizes of standard bear-
ings, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly.
Number Marked
Cylinder BlockCrankshaftUse Bearing
101
112
123
202
213
224
303
314
325
HINT:
EXAMPLE
Cylinder block ”2” + Crankshaft ”1” = Total number 3 (Use bear-
ing ”3”)
Cylinder block main journal bore diameter:
Mark ”1”61.000 to 61.006 mm (2.4016 to 2.4018 in.)
Mark ”2”61.006 to 61.012 mm (2.4018 to 2.4020 in.)
Mark ”3”61.012 to 61.018 mm (2.4020 to 2.4023 in.)
Crankshaft main journal diameter:
Mark ”0”57.004 to 57.010 mm (2.2443 to 2.2445 in.)
Mark ”1”56.998 to 57.004 mm (2.2440 to 2.2443 in.)
Mark ”2”56.992 to 56.998 mm (2.2438 to 2.2440 in.)
Standard size bearing center wall thickness:
Mark ”1”1.976 to 1.979 mm (0.0778 to 0.0779 in.)
Mark ”2”1.979 to 1.982 mm (0.0779 to 0.0780 in.)
Mark ”3”1.982 to 1.985 mm (0.0780 to 0.0781 in.)
Mark ”4”1.985 to 1.988 mm (0.0781 to 0.0783 in.)
Mark ”5”1.988 to 1.991 mm (0.0783 to 0.0784 in.)
(m) Completely remove the Plastigage.
Page 4029 of 5135
A59623
Intake Side:
Front Side:Exhaust Side:
Rear Side:
1.5 mm
(0.059 in.)2.0 mm
(0.079 in.)2.0 mm
(0.079 in.)
A
BA 1.5 mm
(0.059 in.)
B 2.0 mm
(0.079 in.)
A
A
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−55
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
21. INSTALL TIGHT PLUG
(a) Apply adhesive around new tight plugs.
Adhesive: Part No.08833−00070, THREE BOND 1324
or equivalent.
(b) Using SST, tap in the tight plugs as shown tn the illustra-
tion.
SST 09950−60010 (09951−00350), 09950−70010
(09951−07100)
Standard depth:
2.0 mm (0.079 in.) for intake side
2.0 mm (0.079 in.) for exhaust side
1.5 mm (0.059 in.) for front side
1.5 mm (0.059 in.) for rear side A
2.0 mm (0.079 in.) for rear side B
Page 4030 of 5135
A87940
Cylinder Head Side: Lower Side:
Front Side:
A
11 mm (0.433 in.)
20 mm
(0.787 in.)
14 mm (0.55 in.) 8mm
(0.315 in.)
AAA
B B
Protrusion Height: 5.0 mm (0.197 in.)
Protrusion Height: 13 mm (0.512 in.)
BA 14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
22. INSTALL RING PIN
(a) Using a plastic−faced hammer, tap in new ring pins until
their protrusion heights are as specified.
Page 4031 of 5135
A87941
10 mm (0.394 in.)
22 mm
(0.866 in.)6 mm (0.236 in.)
11 m m
(0.433 in.)14 mm
(0.551 in.)
AB Rear Side: Exhaust Side:
C
B
A
C
6 mm (0.236 in.)
A87942
Rear Side: Lower Side:
A
27.5 mm
(1.083 in.)
A (M6) B (M6)28 mm
(1.102
in.)
B
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−57
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
23. INSTALL STRAIGHT PIN
(a) Using a plastic−faced hammer, tap in new straight pins.
Standard protrusion:
13 mm (0.5118 in.) for straight pin A
4.0 mm (0.1575 in.) for straight pin B
5.0 mm (0.1968 in.) for straight pin C
24. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque: 2.9 Nm (30 kgfcm, 27 in.lbf)
Page 4032 of 5135
A87939
6mm
Hexagon
Wrench
A85943
A56044
A56045
A09510Groove
14−58− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
25. INSTALL CYLINDER BLOCK OIL ORIFICE
(a) Using a hexagon wrench (6 mm), install the oil orifice.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
26. INSTALL SUB−ASSY OIL NOZZLE NO.1
(a) Install the 4 oil nozzles with the 4 bolts.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
27. INSTALL CRANKSHAFT
(a) Install the bearing on the cylinder block and bearing cap.
HINT:
Each upper bearing has an oil groove and oil hole and each low-
er bearing does not.
(1) Align the bearing claw with the claw groove of the
cylinder block, then push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, then push in the 5 lower bear-
ings.
(b) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.