Inspection

INSPECTION





1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
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, so always wash the cylinder block at a temperature of 450°f or less.





3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.





4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. INSPECT CYLINDER BORE DIAMETER





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




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: 87.73 mm (3.4539 inch)
If the diameter is greater than maximum, replace the cylinder block.





6. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.
7. INSPECT MAIN BEARING CAP BOLTS





Using vernier calipers, measure the tension portion diameter of the bolt.





Diameter:
If the diameter is less than minimum, replace the stud bolt.
8. CLEAN PISTON





a. Using a gasket scraper, remove the carbon from the piston top.





b. Using a groove cleaning tool or broken ring, clean the piston ring grooves.





c. Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.

9. INSPECT PISTON OIL CLEARANCE

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





a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 26.5 mm (1.04 inch) from the piston head.





Piston diameter:
b. Measure the cylinder bore diameter in the thrust directions. (See step 5 above)
c. Subtract the piston diameter measurement from the cylinder bore diameter measurement.





Oil clearance:
If the oil clearance is greater than maximum, replace all the 8 pistons. If necessary, replace the cylinder block.





HINT: Use 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 RH and LH banks. The RH piston is marked with "R", the LH piston with "L".

10. INSPECT PISTON RING GROOVE CLEARANCE





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





Ring groove clearance:
If the clearance is not as specified, replace the piston.
11. INSPECT PISTON RING END GAP
a. Insert the piston ring into the cylinder bore.





b. 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.





c. Using a feeler gauge, measure the end gap.





Standard end gap:





Maximum end gap:
If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
12. INSPECT PISTON PIN FIT





At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.
13. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod alignment.





Check for bend
Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If bend is greater than maximum, replace the connecting rod assembly.





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

14. INSPECT PISTON PIN OIL CLEARANCE





a. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 inch)





b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 inch)
c. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.





Oil clearance:
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.
15. INSPECT CONNECTING ROD BOLTS





Using vernier calipers, measure the tension portion of the connecting rod bolt.





Diameter:
If the diameter is less than minimum, replace the bolt.
16. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT
a. Place the crankshaft on V-blocks.





b. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.08 mm (0.0031 inch)
If the circle runout is greater than maximum, replace the crankshaft.

17. INSPECT MAIN JOURNALS AND CRANK PINS





a. Using a micrometer, measure the diameter of each main journal and crank pin.





Diameter:
If the diameter is not as specified, check the oil clearance (See disassembly). If necessary, replace the crankshaft.
b. Check each main journal and crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than maximum, replace the crankshaft.