Part 1
Engine Block Clean and InspectTool Required
- J8087 Cylinder Bore Gauge
1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the behind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts.
8. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
10. Inspect the mating surfaces of the transmission case.
Notice: A broken flywheel may result if the transmission case mating surface is not flat.
11. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses:
1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
2. Hold the gauge plate flat against the crankshaft flange.
3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.
4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in).
5. Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).
12. Inspect the crankshaft main bearing bores. Use a bore gauge to measure the bearing bore concentricity and alignment at the following locations:
- The camshaft
- The crankshaft
Important: Recondition the engine block with the crankshaft bearing cap bolts installed and tightened to specification.
13. Ensure that the crankshaft bearing caps are installed correctly. The arrows should point toward the front of the engine.
14. Replace the engine block if the crankshaft bearing bores are out of specification.
15. Use the J8087 to inspect the cylinder bores. Inspect for the following items:
- Wear
- Taper
- Runout
- Ridging
Important: If the bore is worn beyond the limits, refit the bore with oversized pistons. Select the smallest available oversize piston. Refer to piston Selection.
16. Leave sufficient cylinder bore for out-of-round and taper.
Cylinder Boring and Honing
1. Measure the cylinder bore for out-of-round and taper.
2. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100 mm (4 in) below the head gasket surface.
3. Measure the cylinder bores by setting the cylinder gauge dial at zero in the cylinder at the point of the desired measurement. Lock the dial indicator at zero before removing the dial from the cylinder. Measure across the gauge contact points with an outside micrometer, with the gauge at the same zero setting as when the gauge was removed from the cylinder.
4. If dimension (1) is larger than dimension (2) by 0.013 mm (0.0005 in), bore the cylinder for oversize piston and rings.
- If relatively few bores require correction, do not rebore all the cylinders to the same oversize in order to maintain engine balance.
- All oversize service pistons are held to the same weights as the standard size pistons.
5. Fine vertical scratches made by the ring ends do not, by themselves,cause excessive oil consumption. Do not hone the cylinder in order to remove these scratches.
6. If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston rings.
1. Ensure that the hone stones are clean, sharp, and straight.
2. Move the hone slowly up and down to produce a 45 degree crosshatch pattern.
3. Clean the bore thoroughly with soap and water.
4. Dry the bore.
5. Rub clean engine oil in the bore.
6. Remeasure the bore.
7. If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to the bore after washing and drying the bore.
Engine Flywheel Clean and Inspect
1. Clean the flywheel in solvent.
Caution: Wear safety glasses in order to avoid eye damage.
2. Dry the flywheel with compressed air.
3. Inspect the manual transmission flywheel for the following:
- Damaged ring gear teeth.
- Loose or improperly positioned ring gear.
The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel.
- A scored, grooved or damaged friction surface
4. Inspect the automatic transmission flywheel for the following:
- Damaged ring gear teeth
- Stress cracks around the flywheel-to-crankshaft bolt hole locations.
- Welded areas that retain the ring gear onto the flywheel for cracking.
Important: Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate. Install a new flywheel.
Crankshaft and Bearings Clean and Inspect (Inspection)
Tool Required
- J 7872 Magnetic Base Dial Indicator Set
Important: Use care when handling the crankshaft. Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring. Damage to the teeth of the crankshaft position reluctor ring may effect OBD II system performance.
1. Remove the clutch pilot bearing.
2. Clean the crankshaft with solvent.
3. Thoroughly clean all oil passages and inspect for restrictions or burrs.
Caution: Wear safety glasses in order to avoid eye damage.
4. Dry the crankshaft with compressed air.
Important:
Reluctor ring teeth should not have imperfections on the rising or falling edges.
Imperfections of the reluctor ring teeth may effect OBD II system performance.
5. Perform a visual inspection of the crankshaft for damage.
6. Inspect the crankshaft journal for wear (1).
Journal should be smooth with no signs of scoring, wearing, or damage.
7. Inspect the crankshaft journals for grooves of scoring (2).
8. Inspect the crankshaft journals for scratching or wear (3).
9. Inspect the crankshaft journals for pitting or imbedded bearing material.
10. Measure the crankshaft journals for out-of-round.
11. Measure the crankshaft journals for taper.
12. Measure the crankshaft runout.
Using wooden The DTC blocks, support the crankshaft on the front and rear journals.
13. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals.
14. Use the J 7872 in order to measure the runout of the crankshaft rear flange.
1. Compare the measurements to Engine Mechanical Specifications.
2. Replace or repair the crankshaft if the measurements are not within the specifications.
15. Install a new clutch pilot bearing.
A properly installed clutch pilot bearing will be installed until flush to the face of the crankshaft.
16. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
17. Inspect the crankshaft bearings for excessive scoring or discoloration.
18. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
19. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing.
If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced.
Generally, if the lower half is suitable for use, the upper half should also be suitable for us.
Crankshaft and Bearings Clean and Inspect (Bearing Selection)
Tools Required
- J 36660 Torque Angle Meter
- J 8087 Cylinder Bore Checking Gauge
Cleaning and Inspection
1. Clean the crankshaft of the following elements:
- Oil
- Sludge
- Carbon
2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft keyway for nicks or wear
4. Inspect the crankshaft threads.
Important: If cracks, severe gouges or burned spots are found, the crankshaft must be replaced. Slight roughness may be removed with a fine polishing cloth soaked in clean engine oil. Burrs may be removed with a fine oil stone.
5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions:
- Cracks
- Chips
- Gouges
- Roughness
- Grooves
- Overheating (discoloration)
6. Inspect the corresponding crankshaft bearings for embedded foreign material and determine the source.
Important: Note the location of the crankshaft main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.
7. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.
8. The crankshaft bearings are of the precision insert type. The crankshaft bearings are available in standard and various undersizes.
Notice: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will etch the bearing surface.
9. Inspect the outer surfaces of the crankshaft bearings for the following conditions:
- Wear - surface wear indicates either movement of the insert or high spots in the surrounding material (spot wear).
- Overheating or discoloration
- Looseness or rotation indicated by flattened tangs and wear grooves
10. Inspect the thrust surfaces of the main thrust bearing for the following conditions:
- Wear
- Grooving (Grooves are caused by irregularities of the crankshaft thrust surface.)
Important: If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.
11. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure:
1. Tighten the bearing cap to specification.
2. Measure the bearing bore for taper and out-of-round.
3. No taper or out-of-round should exist.
Bearing Selection
1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred.
- Method A yields measurement from which the bearing clearance can be computed.
- Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.
Method A
Important: Do not mix inserts of different nominal size in the same bearing bore.
1. Measure the crankshaft bearing journal diameter with a micrometer in several places 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification.
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.
Method B
Important: Do not mix inserts of different nominal size in the same bearing bore.
1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps.
Notice: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification.
Important: Do not rotate the crankshaft.
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.
Piston and Connecting Rod Disassemble
Tools Required
- J 24086-C Piston Pin Remover/lnstaller
Caution: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury.
1. Disassemble the piston rings. Use a suitable tool in order to expand the rings. Piston rings must not be reused.
Important: Ensure that no load is put on the piston during disassembly.
2. Place the piston and the connecting rod assembly into the J 24086-C and press out the piston pin. Ensure that the flat side or inside of the piston is up when installing the piston and rod assembly into the fork.
Piston, Connecting Rod and Bearings Clean/inspect
Connecting Rod Measurement
1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rods for the following:
- Signs of being twisted, bent, nicked, or cracked
- Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOT scrape the rod or rod cap.
4. Measure the piston pin to connecting rod bore using the following procedure:
1. Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact.
2. Using an inside micrometer, measure the connecting rod piston pin bore.
3. Subtract the piston pin bore diameter from the piston pin diameter.
4. The interference fit should not be less than 0.025 mm (0.0098 in).
5. If there is not a great enough interference fit, replace the piston pin.
Piston Measurement
1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Make sure oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions:
- Cracked ring lands, skirts, or pin bosses
- Ring grooves for nicks, burrs that may cause binding
- Warped or worn ring lands
- Eroded areas at the top of the piston (1)
- Scuffed or damaged skirts (2)
- Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure:
1. Piston pin bores and pins must be free of varnish or scuffing.
2. Use an outside micrometer to measure the piston pin in the piston contact areas.
3. Using an inside micrometer, measure the piston pin bore.
4. Subtract the measurement of the piston pin bore from the piston pin. The clearance should not exceed 0.008-0.016 mm (0.0003-0.0008 in).
5. If the clearance is excessive, determine which component is out of specification.
6. Measure the piston ring end gap using the following procedure:
1. Place the piston ring in the area of the bore where the piston ring will travel (approximately 25 mm or 1 inch down from the deck surface). Be sure the ring is square with the cylinder bore by positioning the ring with the piston head.
2. Measure the end gap of the piston ring with feeler gages. Compare the measurements with those provided below:
- The top compression ring end gap should be 0.25-0.50 mm (0.010-0.020 in).
- The second compression ring end gap should be 0.25- 0.50 mm (0.010-0.020 in).
- The oil ring end gap should be 0.25-1.27 mm (0.08- 0.8002 in).
3. If the clearance exceeds the provided specifications, the piston rings must be replaced.
4. Repeat the procedure for all the piston rings.
7. Measure the piston ring side clearance using the following procedure:
1. Roll the piston ring entirely around the piston ring groove. If any binding is caused by the ring groove, dress the groove with a fine file. If any binding is caused by a distorted piston ring, replace the ring.
2. With the piston ring on the piston, use feeler gages to check clearance at multiple locations.
3. The clearance between the surface of the piston ring and the ring land should be no greater than 0.027 mm (0.0011 in).
4. If the clearance is greater than specifications, replace the piston rings.
8. The top compression ring may be installed with either side up. There is a locating dimple on the 2nd compression ring near the end for identification of the top side. Install the 2nd compression ring with the dimple facing up.
9. If the new ring does not reduce the clearance to 0.027 mm (0.0011 in) or less, install a new piston.
10. Measure piston width using the following procedures:
1. Using an outside micrometer, measure the width of the piston 11 mm (0.437 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin.
2. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter.
3. The proper clearance specification for the piston is 0.0015-0.047 mm (0.0006-0.0018 in).
11. If the clearance specification for the piston is 0.015-0.047 mm (0.0006-0.0018 in).
Piston Selection
Important:
Measurement of all components should be taken with components at normal room temperature.
For proper piston fit, the engine block cylinder bores must not have excessive wear or taper.
A used piston and pin set may be reinstalled if, after cleaning and inspection, they are within specifications.
1. Inspect the engine block cylinder bore.
Refer to Engine Block Clean and Inspect.
2. Inspect the piston and the piston pin.
Refer to Piston, Connecting Rod and Bearings Clean/Inspect.
3. Use a bore gauge and measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
4. Measure the bore gauge with a micrometer and record the reading.
5. With a micrometer or caliper at a right angle to the piston, measure the piston 11 mm (0.437 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance.
Refer to Engine; Specifications; Mechanical.
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder.