Part 1

Engine Block Clean and Inspect

Tools Required
- J 8087 Cylinder Bore Gauge

Caution: Wear safety glasses in order to avoid eye damage.




1. Clean all the remaining sealing or gasket material from the sealing surfaces.
2. Boil the engine block in a caustic cleaning solution.
3. Flush the engine block with clean water or steam.
4. Clean the cylinder bores.
5. Clean the oil galleries and the oil passages.
6. Clean the scale and the deposits from the coolant passages.

Notice: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

7. Clean the engine block cylinder head bolt holes.
8. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil.
9. Inspect the following areas:
- Coolant jackets (1) for cracks
- Cylinder bores (2) for scratches or gouging
- Valve lifter bores (3) for excessive scoring or wear
- Threaded holes (4) for damage
- Crankshaft bearing webs (5) for cracks
- Crankshaft bearing caps (6) and the crankshaft bearing bores (7)for damage
- The crankshaft bearing bores should be round and uniform when measuring the inside diameter (ID).
- The surface where the crankshaft bearings contact the crankshaft bearing bore should be smooth.
- If a crankshaft bearing cap is damaged and requires replacement,replace the crankshaft bearing cap first, then rebore the engine block crankshaft bearing bores and check for the proper alignment. Finally, check the crankshaft for the proper clearances.
- Expansion cup plug bores (8) for damage
- Engine block (9) for cracks or damage Engine mount bosses (10) for damage




10. Measure the cylinder bores for taper and out-of-round.
1. Depress the plunger on the J 8087 (0.275 in) or until the J 8087 enters the cylinder bore.
2. Center the J 8087 in the cylinder bore and turn the indicator dial to 0.
3. Move the J 8087 up and down the cylinder bore to determine the cylinder bore taper. Refer to Engine; Specifications; Mechanical.
4. Turn the J 8087 to different points around the cylinder bore to determine the cylinder bore out-of-round condition. Refer to Engine; Specifications; Mechanical.

Cylinder Boring and Honing

Cylinder Honing

Caution: Wear safety glasses in order to avoid eye damage.




1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication.
- Use only clean sharp stones of the proper grade for the amount of material to be removed.
- Dull, dirty stones cut unevenly and generate excessive heat.
- DO NOT hone to a final grade with a coarse or medium-grade stone.
- Leave sufficient metal so that all the stone marks will be removed with the fine grade stones.
- Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern at 45 - 65 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder bore.
- Repeatedly check the cylinder bore fit with the selected piston.
- All measurements of the piston or cylinder bore should be made with the components at normal room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore.
Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore.
- The finish marks should be clean but not sharp.
- The finish marks should be free from imbedded particles or torn or folded metal.
4. By measuring the selected piston at the sizing point and then by adding the average of the clearance specification, the final cylinder bore honing dimension required can be determined.
5. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
6. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent.
1. Scrub the cylinder bores with a stiff bristle brush.
2. Rinse the cylinder bores thoroughly with clean hot water.
3. Dry the cylinder bores with a clean rag.
4. Do not allow any abrasive material to remain in the cylinder bores.
- Abrasive material may cause premature wear of the new piston rings and the cylinder bores.
- Abrasive material will contaminate the engine oil and may cause premature wear of the bearings.
7. Perform final measurements of the piston and the cylinder bore.
8. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
9. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Boring Procedure

Caution: Wear safety glasses in order to avoid eye damage.




1. Before starting the honing or reboring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline.
2. File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar.
3. Follow the instructions furnished by the manufacturer regarding use of the boring equipment.
4. When reboring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction.
5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly.
6. When making the final cut with the boring bar, leave 0.03 mm(0.001 in) on the cylinder bore diameter for finish honing. This gives the required position to the cylinder clearance specifications. (Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons, the piston rings, and the cylinder bores).

Crankshaft and Bearings Clean and Inspect

Tools Required
- J 7872 Magnetic Base Dial Indicator
- J 36660 Electronic Torque Angle Meter

Caution: Wear safety glasses in order to avoid eye damage.

Important: Use care when handling the crankshaft. Avoid damage to the crankshaft bearing surfaces.




1. Clean the crankshaft in cleaning solvent. Remove all sludge or restrictions from the oil passages.
2. Dry the crankshaft with compressed air.




3. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth, do not scratch the crankshaft bearing surfaces.
4. Dry the crankshaft bearings with compressed air.




5. Inspect the crankshaft for the following:
- Crankshaft journals (1) should be smooth with no evidence of scoring or damage.
- Deep grooves (2)
- Scratches or uneven wear (3)
- Pitted surfaces (4)
- Wear of damage to the thrust journal surfaces
- Scoring or damage to the front or rear seal surface
- Restrictions to the oil passages
- A loose or damaged rear oil gallery plug damage to the threaded bolt holes




6. Inspect the crankshaft balancer key (1), the keyway (2), and the threaded hole (3) for damage.




7. Measure the crankpins for out-of-round and taper.




8. Use a suitable support to support the crankshaft on the front and rear journals.
9. Use the J 7872 in order to measure the crankshaft journal runout. The crankshaft runout should not exceed 0.025 mm (0.001 in).




10. Measure the crankshaft end play.

Important: In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearings, the crankshaft bearing caps, and the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened to specifications.

1. Firmly thrust the crankshaft first rearward, then forward. This will align the crankshaft rear bearings and the crankshaft thrust surfaces.
2. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance. Refer to Engine; Specifications; Mechanical.
3. If the correct end play cannot be obtained, verify that the correct size crankshaft bearing has been installed. Refer to Engine Mechanical Specifications.
4. Inspect the crankshaft for binding. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, then loosen the crankshaft bearing cap bolts, one crankshaft bearing cap at a time, until the tight crankshaft bearing is located.
Burrs on the crankshaft bearing cap, foreign matter between the crankshaft bearing and the engine block or the crankshaft bearing cap, or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing.




11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.




12. Inspect the crankshaft bearings for excessive scoring or discoloration.
13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing.




14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings.
- If the lower half of the crankshaft bearing is worn or damaged, both the upper and lower halves of the crankshaft bearing should be replaced.
- Generally, if the lower half of the crankshaft bearing is suitable for use, the upper half of the crankshaft bearing should also be suitable for use.

Bearing Clearance Measuring Procedures

The crankshaft bearings are of the precision insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required. The service crankshaft bearings are available in the standard size and an undersize.
The selective fitting of the crankshaft bearings are necessary in production in order to obtain close tolerances. For this reason, in one journal bore you may use one-half of a standard crankshaft bearing with one-half of a undersize crankshaft bearing.
In order to determine the correct replacement crankshaft bearing size,the crankshaft bearing clearance must be measured accurately. Either the micrometer or plastic gauge method may be used; however, the micrometer method gives more reliable results and is preferred.

Micrometer Method for Crankshaft Bearings




1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements.
2. Determine the taper and the out-of-round of the crankshaft journal. Refer to Engine; Specifications; Mechanical.




3. Install the crankshaft bearings into the engine block.




4. Install the crankshaft bearings into the crankshaft bearing caps




5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.
6. Install the crankshaft bearing cap bolts.
1. Tighten the crankshaft bearing cap bolts on the first pass to 2O N.m (15 lb ft).
2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660.
7. Measure the crankshaft bearing inside diameter (ID) at the top and the bottom using an inside micrometer.
8. In order to determine the crankshaft bearing clearance, subtract the journal diameter from the crankshaft bearing ID.
9. Compare the crankshaft bearing clearance to the specifications. Refer to Engine; Specifications; Mechanical.
10. If the crankshaft bearing clearances exceeds specifications, install the new crankshaft bearings as follows:
1. Measure the crankshaft bearing inside diameter (ID) at the top and the bottom using an inside micrometer.
2. Compare the crankshaft bearing clearance to the specifications. Refer to Engine; Specifications; Mechanical.
11. Replace or repair the crankshaft if the proper clearances cannot be obtained.

Micrometer Method for Connecting Rod Bearings

Notice: Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.




1. Measure the crankpin diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements.
2. Determine the taper and the out-of-round. Refer to Engine; Specifications; Mechanical.
3. Install the connecting rod bearings into the connecting rod cap and the connecting rod.
4. Install the connecting rod caps and the nuts.
1. Tighten the connecting rod nuts in the first pass, evenly to 27 N.m(20 lb ft).
2. Tighten the connecting rod nuts in the final pass an additional 70 degrees using the J 36660.
5. Measure the connecting rod bearing inside diameter (ID) at the top and the bottom using an inside micrometer.
6. Compare the connecting rod bearing clearance to the specifications. Refer to Engine; Specifications; Mechanical.
7. If the connecting rod bearing clearance is within specifications,the connecting rod bearing is satisfactory.
- Replace the connecting rod bearing if the clearance is not within specifications.
- Always replace both the upper and the lower connecting rod bearings as an assembly
8. A standard or undersize connecting rod bearing combination may result in the proper clearance.
If the proper connecting rod bearing clearance cannot be achieved using the standard or the undersize connecting rod bearings, it will be necessary to replace or repair the crankshaft.

Plastic Gauge Method for Main or Connecting Rod Bearings




1. Install the crankshaft bearings into the engine block.




2. Install the crankshaft.




3. Install the gauging plastic the full width of the journal.




4. Install the crankshaft bearings into the crankshaft bearing caps.




5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.
6. Install the crankshaft bearing cap bolts.
1. Tighten the crankshaft bearing cap bolts on the first pass to 2O N.m (15 lb ft).
2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660.




7. Remove the crankshaft bearing cap bolts.
8. Remove the crankshaft bearing caps. The gauging plastic may adhere to either the crankshaft bearing journal or the crankshaft bearing surface.




9. Without removing the gauging plastic, measure the compressed width at the widest point using the graduated scale on the edge of the gauging plastic envelope.
If the flattened gauging plastic tapers toward the middle or the ends,there may be a difference in clearance indicating taper, low spot or other irregularity of the crankshaft bearing or the crankshaft bearing journal.
Normally the crankshaft bearing journals wear evenly and are not out-of-round. However, if a crankshaft bearing is being fitted to an out-of-round 0.0254 mm (0.001 in) (maximum) crankshaft bearing journal, be sure to fit to the maximum diameter of the crankshaft bearing journal. If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal is excessively out-of-round, the interference between the crankshaft bearing and the crankshaft bearing journal will result in rapid crankshaft bearing failure.
- If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications,replace the crankshaft bearing.
Always replace both the upper and lower crankshaft bearings as a unit.
- A standard or undersize crankshaft bearing combination may result in the proper clearance. If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings, it maybe necessary to repair or replace the crankshaft.

Notice: Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.

10. Remove the flattened gauging plastic.
11. Measure the remaining crankshaft and connecting rod bearing journals.

Connecting Rod Side Clearance Measuring Procedure




1. Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance. Refer to Engine; Specifications Mechanical.
2. Connecting rod side clearances may also be measured with a dial indicator set.

Crankshaft Balancer Clean and Inspect

Caution: Wear safety glasses in order to avoid eye damage.




1. Clean the crankshaft balancer in cleaning solvent.
2. Dry the crankshaft balancer with compressed air.
3. Inspect the crankshaft balancer for the following:
- Loose or improperly installed front groove pin (1) (crankshaft balancer)
A properly installed front groove pin should be installed until flush or below flush with the face of the crankshaft balancer.

Important: A crankshaft front oil sealing surface with excessive scoring, grooves, rust, or other damage must be replaced.

- Worn, grooved, or damaged crankshaft front oil sealing surface (2)
Minor imperfections on the crankshaft balancer crankshaft front oil seal surface may be removed with a polishing compound or fine grade emery cloth.
- Worn, chunking, or deteriorated rubber (3) between the hub and pulley
- Worn or damaged keyway (4)
- Worn or damaged bolt hole threads (5)

Engine Flywheel Clean and Inspect

1. Clean the engine flywheel in cleaning solvent.

Caution: Wear safety glasses in order to avoid eye damage.

2. Dry the engine flywheel with compressed air.




3. Inspect the engine flywheel (manual transmission) for loose or improperly installed flywheel weights.
A properly installed flywheel weight should be installed until flush or below flush with the face of the engine flywheel.




4. Inspect the engine flywheel (manual transmission) for the following:
- Damaged ring gear teeth (4)
- Loose or improperly positioned ring gear
The ring gear has an interference fit onto the engine flywheel and should be positioned completely against the flange of the engine flywheel.
- Pitted friction surface (1)
- Scoring or grooves (2)
- Rust or other damage (3)




5. Inspect the engine flywheel (automatic transmission) for the following:
- Damaged ring gear teeth
- Missing balance weights
- Stress cracks around the flywheel-to-crankshaft bolt hole locations.

Important: Do not attempt to repair the welded areas that retain the ring gear to the engine flywheel plate. Install a new engine flywheel.

- Welded areas that retain the ring gear onto the engine flywheel for cracking.

Piston and Connecting Rod Disassemble

Tools Required
- J 24086-C Piston Pin Remover/Installer

Caution: Wear safety glasses in order to avoid eye damage.




1. Remove the piston rings from the pistons.




2. Press the piston pin from the connecting rod using the J 24086-C.
The piston pin has an interference fit into the connecting rod, and is full floating in the piston.




3. Mark, separate, and organize the parts for assembly.

Piston, Connecting Rod and Bearings Clean/Inspect

Important:
Measurement of all components should be taken with the components at room temperature.
Do not use a wire brush in order to clean any part of the piston.




1. Clean the piston and connecting rod in solvent.

Caution: Wear safety glasses in order to avoid eye damage.

2. Dry the components with compressed air.




3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.




5. Inspect the piston for the following:
- Eroded areas (1) on the top of the piston
- Scuffed or damaged skirt (2)
- Damage to the pin bore (3)
- Cracks in the piston ring lands, the piston skirt, or the pin bosses
- Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind
6. Inspect the piston pin for scoring, wear or other damage.




7. Measure the piston ring-to-piston ring groove side clearance.
1. Insert the edge of the piston ring into the piston ring groove.
2. Roll the piston ring completely around the piston
- If binding is caused by a distorted piston ring groove, MINOR imperfections may be removed with a fine file.
- If binding is caused by a distorted piston ring, replace the piston ring.




8. Measure the piston ring side clearance with a feeler gauge.
9. If the side clearance is too small, try another piston ring set.
10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly.
11. To determine the proper piston ring side clearance, refer to Engine; Specifications; Mechanical.




12. To determine piston pin-to-bore clearance use a micrometer and measure the piston pin.




13. To determine piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore.
14. To determine the piston pin-to-bore clearance, subtract the piston pin diameter from the piston pin bore diameter.




15. Measure the piston for out-of-round.
1. With a micrometer at a right angle to the piston, measure the piston at 11 mm (0.433 in) from the bottom of the skirt.
2. Measure the piston at three different points 120 degrees apart and compare the readings, refer to Engine; Specifications; Mechanical.
3. If the clearance is not within specifications, replace the piston and pin as an assembly.




16. Inspect the connecting rod for an out-of-round bearing bore.




17. Inspect the connecting rod for twisting.
18. Inspect the connecting rod for damage to the bearing cap stud threads.




19. Measure the piston compression ring end gap.

Important: Fit each compression ring to the cylinder in which it will be used.

1. Place the compression ring into the cylinder bore.
2. Push the compression ring into the cylinder bore to approximately 6.5 mm (0.25 in) above the ring travel.
The ring must be square to the cylinder wall.
3. Use a feeler gage in order to measure the end gap.
4. Select another size ring set if the end gap exceeds specifications.

Piston Selection

Tools Required
- J 8087 Cylinder Bore Gauge

Important:
Measurements of all components should be taken with the components at normal room temperature.
For proper piston fit, the engine block cylinder bores should not have excessive wear or taper.
A used piston and piston pin set may be reinstalled if, after cleaning and inspection, the piston and piston pin are within specifications.




1. Inspect the engine block cylinder bore. Refer to Engine Block Clean and Inspect.
2. Inspect the piston and pin. Refer to Piston, Connecting Rod and Bearings Clean/Inspect.
3. Use the J 8087 in order to measure the cylinder bore diameter. Measure at a point 64 mm(2.5 in) from the top of the cylinder bore.




4. Measure the J 8087 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 (0.433 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. Refer to Engine; Specifications; Mechanical.
7. If the proper clearance cannot be obtained, then select another piston and measure the clearances.
If the proper fit cannot be obtained, the cylinder bore may require honing or boring.
8. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder.