Engine Unit, Inspection

ENGINE UNIT

COMPONENTS:

INSPECTION
1. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.
^ Check the belt for any defects, as shown in the illustrations. Also, check these points.

a. If there is premature parting:
^ Check for proper installation.
^ Check the timing cover gasket for no damage and proper installation.
b. If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
c. If there is noticeable wear or cracks on the belt, check to see if there are nicks on the side of the idler pulley lock and water pump.
d. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
e. If there is noticeable wear on the belt teeth:
^ Check the timing cover for damage.
^ Check that the gasket has been installed correctly
^ Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.

2. INSPECT CAMSHAFT
a. Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the runout is greater than the maximum, replace the camshaft.

b. Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height:

Minimum Cam Lobe Height:

If the cam lobe height is less than the minimum, replace the camshaft.

c. Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.

3. INSPECT CYLINDER HEAD SET BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than the minimum, replace the bolt.
4. CLEAN CYLINDER BLOCK

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.

5. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.

6. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Specified diameter: 92.000 to 92.132 mm (3.6220 to 3.6272 inch)
If the measured diameters is greater than the maximum, replace the cylinder block.

7. INSPECT W/PIN PISTON SUB-ASSEMBLY
a. Using a micrometer, measure the diameter of the piston. When you measure the diameter, attach the micrometer to a location where 13.0 mm (0.512 inch) above from the piston bottom and meets at the right angles to the piston pin hole.
Piston diameter: 91.953 to 91.967 mm (3.6202 to 3.6207 inch)
8. INSPECT PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 inch)
Maximum oil clearance: 0.130 mm (0.0051 inch)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.

9. INSPECT CONNECTING ROD SUB-ASSEMBLY
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If misalignment is greater than the maximum, replace the connecting rod assembly.

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

10. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Bush inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)

b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
c. Subtract the piston pin diameter measurement from the bush inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and the piston pin together.

11. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bush.
SST 09222-30010

12. INSTALL CONNECTING ROD SMALL END BUSH
a. Align the oil holes of a new bush and the connecting rod.

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

c. Using a pin hole grinder, hone the bushing to obtain the standard clearance between the bush and piston pin.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)

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

13. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
If the clearance is not as specified, replace the piston.

14. INSPECT PISTON RING END GAP
a. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.

b. 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, replace the cylinder block.

15. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.20 to 7.30 mm (0.2830 to 0.2870 inch)
Minimum diameter: 7.0 mm (0.2760 inch)
If the diameter is less than the minimum, replace the bolt.

16. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.50 to 7.60 mm (0.2950 to 0.2990 inch)
Minimum diameter: 7.20 mm (0.2830 inch)
If the diameter is less than the minimum, replace the bolt.

17. INSPECT CRANKSHAFT
a. Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than the maximum, replace the crankshaft.

b. Using a micrometer, measure the diameter of each main journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 inch)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
c. Check each main journal 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.

d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
If the diameter is not as specified, check the oil clearance.
e. Check each 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.