Inspection

ENGINE UNIT

COMPONENTS:

INSPECTION
1. INSPECT CYLINDER BLOCK SUB-ASSEMBLY

a. Clean the cylinder block.
1 Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2 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.

b. Inspect for flatness.
1 Using a precision straightedge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If the warpage is greater than the maximum, replace the cylinder block.

c. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 8 cylinders and replace all 8 pistons. If necessary, replace the cylinder block.

d. Inspect the cylinder bore diameter.

HINT: There are 3 sizes of the standard cylinder bore diameter, marked 1, 2 and 3 accordingly The mark is stamped on the top of 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:

Maximum diameter: 94.230 mm (3.7098 inch)
If the diameter is greater than the maximum, rebore all 8 cylinders and replace all 8 pistons. If necessary, replace the cylinder block.

e. Remove the cylinder ridge.

HINT: If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.

2. INSPECT PISTON SUB-ASSEMBLY WITH PIN

a. 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.

b. Inspect the piston oil clearance.

HINT: There are 3 standard diameter sizes, marked 1, 2 and 3. The mark is stamped on the piston top.

1 Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 inch) from the piston head.

Standard Piston Diameter:

2 Measure the cylinder bore diameter in the thrust directions.

3 Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.090 to 0.111 mm (0.0035 to 0.0044 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)
If the oil clearance is greater than the maximum, replace all 8 pistons and rebore all 8 cylinders. If necessary, replace the cylinder block.

HINT: Use a new cylinder block:
^ Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
^ The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and 2, the RH piston with 2 cavities and 2.

c. Inspect the piston pin fit.
1 Heat the piston to approximately 60°C (140°F) and push the piston pin into the piston pin hole with your thumb.

d. Using a micrometer, measure the piston pin diameter.
Standard piston pin diameter: 21.997 to 22.009 mm (0.8660 to 0.8664 inch)
3. INSPECT PISTON RING SET

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

Standard Ring Groove Clearance:

If the clearance is not as specified, replace the piston.

b. Inspect the piston ring end gap.
1 Insert the piston ring into the cylinder bore.
2 Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 inch) from the top of the cylinder block.

3 Using a feeler gauge, measure the end gap.

Standard End Gap:

Maximum End Gap:

If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, rebore all 8 cylinders or replace the cylinder block sub-assembly.
4. INSPECT CONNECTING ROD SUB-ASSEMBLY

a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1 Check if the connecting rod is bent.
Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the bend is greater than the maximum, replace the connecting rod.

2 Check if the connecting rod is twisted.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than the maximum, replace the connecting rod sub-assembly.

5. INSPECT PISTON PIN OIL CLEARANCE
a. Inspect the piston pin oil clearance.
1 Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Standard bush inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)
If the bushing inside diameter is not as specified, check the oil clearance.
2 Subtract the piston pin diameter measurement from the bush inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and piston pin with a new piston and pin set.

6. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion of the connecting rod bolt.
Standard diameter: 7.200 to 7.300 mm (0.2835 to 0.2874 inch)
Minimum diameter: 7.00 mm (0.2756 inch)
If the diameter is less than the minimum, replace the bolt.

7. INSPECT CRANKSHAFT BEARING CAP BOLT
a. Using a vernier caliper, measure the tension portion diameter of the main bearing cap bolt.
Standard diameter: 10.760 to 10.970 mm (0.4236 to 0.4319 inch)
Minimum diameter: 10.40 mm (0.4094 inch)
If the diameter is less than the minimum, replace the cap bolt.

8. INSPECT CRANKSHAFT
a. 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: 0.04 mm (0.0016 inch)
If the circle runout is greater than the maximum, replace the crankshaft.

b. Inspect the main journals and crank pins.
1 Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter: 66.988 to 67.000 mm (2.6373 to 2.6378 inch)
Standard crank pin diameter: 51.982 to 52.000 mm (2.0465 to 2.0472 inch)
If the diameter is not as specified, check the oil clearance. If necessary, 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 (0.0008 inch)
If the taper and out of round is greater than the maximum, replace the crankshaft.