Inspection and Replacement

INSPECTION





1. CLEAN CYLINDER BLOCK
a. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
b. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.





2. INSPECT CYLINDER BLOCK SURFACE FOR FLATNESS
Using precision straight edge and feeler gauge, measure the top surfaces of the cylinder block for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.





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





4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 86.000 - 86.013 mm (3.3858 - 3.3863 inch)
Maximum diameter: 86.02 mm (3.3866 inch)
If the diameter is greater than maximum, replace the cylinder block.





5. 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.





6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
Standard diameter: 9.96 - 9.97 mm (0.3921 - 0.3925 inch)
Minimum diameter: 9.7 mm (0.382 inch)
If the diameter is less than minimum, replace the bolt.
7. 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.





8. INSPECT PISTON OIL CLEARANCE
a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 34 mm (1.34 inch) from the piston head.
Piston diameter: 85.945 - 85.965 mm (3.3837 - 3.3844 inch)
b. Measure the cylinder bore diameter in the thrust directions (See step 4).
c. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.035 - 0.068 mm (0.0014 - 0.0027 inch)
Maximum oil clearance: 0.10 Am (0.0039 inch)
If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.





9. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove.





Ring groove clearance

If the clearance is not as specified, replace the piston.
10. 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 ring end gap.





Standard ring end gap





Maximum ring 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.





11. INSPECT PISTON PIN FIT
At 80°C (176°F), you should be able to push the piston pin into the piston pin hole with your thumb.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a feeler gauge and rod aligner, check the connecting rod alignment.





- Check for out-of-alignment.
Maximum out-of-alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If out-of-alignment 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.

13. 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 in side diameter measurement.
Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.





14. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the minimum diameter of the compressed bolt at the measuring point.
Standard diameter: 8.1 - 8.3 mm (0.319 - 0.327 inch)
Minimum diameter: 8.0 mm (0.315 inch)
If the diameter is less than minimum, replace the connecting rod bolt.





15. INSPECT CRANKSHAFT FOR RUNOUT
a. Place the crankshaft on V-blocks.
b. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than maximum, replace the crank shaft.
16. INSPECT MAIN JOURNALS AND CRANK PINS





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





Main journal diameter





Crank pin diameter

If the diameter is not as specified, check the oil clearance.
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 or out-of-round is greater than maximum, grind or replace the crankshaft.
17. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS
- Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 16).
- Install new main journal and/or crank pin undersized bearings.

REPLACEMENT
1. REPLACE CONNECTING ROD BUSHING





a. Using SST and a press, press out the bushing.
SST 09222-30010
b. Align the oil holes of a new bushing and the connecting rod.





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





d. Using a pin hole grinder, bore the bushing to obtain the standard specified clearance between the bushing and piston pin.





e. Check the piston pin fit at room temperature. Coat the piston pin with engine oil and push it into the connecting rod with your thumb.
2. REPLACE CRANKSHAFT FRONT OIL SEAL

HINT: There are 2 methods (a. and b.) to replace the oil seal.
a. If the oil pump is removed form the cylinder block.





1) Using a screwdriver, pry out the oil seal.





2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09316-60011 (09316-00011)
3) Apply MP grease to the oil seal lip.
b. If the pump is installed on the cylinder block.





1) Using a knife, cut off the oil seal lip.
2) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

3) Apply MP grease to a new oil seal lip.





4) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge.
SST 09316-60011 (09316-00011)
3. REPLACE CRANKSHAFT REAR OIL SEAL

HINT: There are 2 methods (a. and b.) to replace the oil seal.

a. If the rear oil seal retainer is removed from the cylinder block.





1) Using a screwdriver and hammer, tap out the oil seal.





2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
3) Apply MP grease to the oil seal lip.
b. If the rear seal retainer is installed on the cylinder block.





1) Using a knife, cut off the oil seal lip.
2) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

3) Apply MP grease to a new oil seal lip.





4) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 0922-15030, 09950-70010 (09951-07100)