Part 2

OVERHAUL (CONTINUED)
11. INSPECT PISTON





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 sizes of the standard piston diameter, marked 1, 2 or 3 accordingly. 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.





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 the 8 pistons and rebore all the 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 approx. 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.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
12. INSPECT PISTON RING SET





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





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 the 8 cylinders or replace the cylinder block sub-assembly.
13. INSPECT CONNECTING ROD SUB-ASSEMBLY





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





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





b. Inspect the piston pin oil clearance.
1 Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)





2 Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
3 Subtract the piston pin diameter measurement from the bushing 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 connecting rod sub-assembly. If necessary, replace the piston and piston pin as a set.





14. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bushing.
SST 09222-30010
15. INSTALL CONNECTING ROD SMALL END BUSH





a. Align the oil holes of a new bushing and the connecting rod.





b. Using SST and a press, press in the bushing.
SST 09222-30010





c. Using a pin hole grinder, hone the bushing to obtain the specified clearance between the bushing and piston pin.





d. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.





16. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter 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.





17. INSPECT CRANKSHAFT BEARING CAP BOLT
a. Using vernier calipers, measure the thread outside diameter of the crankshaft 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.
18. 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 crankshaft journals and crank pins.
1 Using a micrometer, measure the diameter of each crankshaft journal and crank pin.
Crankshaft journal diameter: 66.988 to 67.000 mm (2.6373 to 2.6378 inch)
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 crankshaft 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.





19. INSTALL TIGHT PLUG





a. Apply adhesive to the tight plug.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Using SST and a hammer, tap in a new tight plug as shown in the illustration.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)





20. INSTALL STUD BOLT