Part 2
ENGINE UNIT INSPECTION continued
24. INSPECT INNER COMPRESSION SPRING
a. Using vernier calipers, measure the free length of the inner compression spring.
Free length: 46.51 mm (1.8311 inch)
If the free length is not as specified, replace the spring.
b. Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 1.0 mm (0.039 inch)
Maximum angle (reference): 20
If the deviation is greater than the maximum, replace the spring.
25. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 inch)
b. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
Standard Clearance:
Maximum Oil Clearance:
For intake side: If the clearance is greater than the maximum, replace the intake valve and intake guide bush. For exhaust side: If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.
26. INSPECT CAMSHAFT THRUST CLEARANCE
a. Inspect the RH bank camshafts.
(1) Install the RH bank camshafts.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
Maximum thrust clearance: 0.15 mm (0.006 inch)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
b. Inspect the LH bank camshafts.
(1) Install the LH bank camshafts.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
Maximum thrust clearance: 0.15 mm (0.006 inch)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
27. INSPECT CAMSHAFT OIL CLEARANCE
a. Clean the bearing caps, camshaft housing and camshaft journals.
b. Place the camshafts on the camshaft housing.
c. Lay a strip of Plastigage across each of the camshaft journals.
d. Install the bearing caps.
NOTICE: Do not turn the camshaft.
e. Remove the bearing caps.
f. Measure the Plastigage at its widest point.
Standard Oil Clearance:
Maximum Oil Clearance:
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
g. Clean the bearing caps, camshaft housing and camshaft journals.
h. Place the camshafts on the camshaft housing.
i. Lay a strip of Plastigage across each of the camshaft journals.
j. Install the bearing caps.
NOTICE: Do not turn the camshaft.
k. Remove the bearing caps.
l. Measure the Plastigage at its widest point.
Standard Oil Clearance:
Maximum Oil Clearance:
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
28. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 to 0.40 m (0.0059 to 0.0157 inch)
Maximum thrust clearance: 0.50 mm (0.020 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
29. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.
HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.
b. Remove the 2 connecting rod cap bolts.
c. Using the 2 removed connecting rod caps bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
HINT: Keep the lower bearing inserted to the connecting rod cap.
d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pitting and scratches.
f. Lay a strip of Plastigage on the crank pin.
g. Check that the front mark of the connecting rod cap is facing forward.
h. Install the connecting rod cap.
NOTICE: Do not turn the crankshaft.
i. Remove the 2 bolts and connecting rod cap.
j. Measure the Plastigage at its widest point.
Standard oil clearance: 0.045 to 0.067 mm (0.0018 to 0.0026 inch)
Maximum oil clearance: 0.070 mm (0.0028 inch)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.
Connecting Rod Diameter:
HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 and 4 mark on its surface. connecting rod diameter:
Standard Bearing Center Wall Thickness:
Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
k. Completely remove the Plastigage.
30. INSPECT CRANKSHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance: 0.30 mm (00118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 inch)
31. INSPECT CYLINDER BLOCK FOR WARPAGE
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.07 mm (0.0028 inch)
If the warpage is greater than the maximum, replace the cylinder block.
b. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.
32. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter: 87.500 to 87.512 mm (3.4449 to 3.445 inch)
Maximum diameter: 87.700 mm (3.4527 inch)
If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.
33. INSPECT WITH PIN PISTON SUB-ASSEMBLY
a. Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified.
Distance: 11.1 mm (0.437 inch)
Standard diameter: 87.476 to 87.486 mm (3.4439 to 3.4443 inch)
Maximum diameter: 87.346 mm (3.4388 inch)
34. INSPECT PISTON OIL CLEARANCE
a. Measure the cylinder bore diameter in the thrust directions.
b. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.014 to 0.036 mm (0.0006 to 0.0014 inch)
Maximum oil clearance: 0.06 mm (0.0024 inch)
If the oil clearance is greater than the standard, replace all the pistons. If necessary, replace the cylinder block.
35. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
Ring Groove Clearance:
If the clearance is not as specified, replace the piston.
36. 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, 110 mm (4.33 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 the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.
37. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the piston pin hole.
Piston Pin Hole Inside Diameter:
b. Using a micrometer, measure the piston pin diameter.
Piston Pin Diameter:
c. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance: 0.002 to 0.004 mm (-0.00004 to 0.00002 inch)
Maximum oil clearance: 0.015 mm (0.0006 inch)
If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.
d. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing Inside Diameter:
e. 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: 0.03 mm (0.0012 inch)
If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.
38. INSPECT CONNECTING ROD
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for out-of-alignment.
Maximum out-of-alignment: 0.05 mm (0.0020 inch) per 100 mm (0.94 inch)
If the out-of- alignment is greater the than 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.
39. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)
If the diameter is less than the minimum, replace the bolt.
40. INSPECT CRANKSHAFT
a. Inspect for circle runout.
(1) Place the crankshaft on the V-blocks.
(2) 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 the maximum, replace the crankshaft.
b. Inspect the main journals.
(1) Using a micrometer, measure the diameter of each main journal.
Standard journal diameter: 60.988 to 61.00 mm (2.4011 to 2.4016 inch)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) 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.
c. Inspect the crank pin.
(1) 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. If necessary, replace the crankshaft
(2) 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.
41. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE: Main bearings come in widths of 18.0 mm (0.709 inch) and 21.0 mm (0.827 inch). Install the 21.0 mm (0.827 inch) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 inch) bearings in the No.2 and No.3 positions.
a. Clean the main journal, and the both surfaces of the bearing.
b. Install the upper bearing.
(1) Install the upper bearing to the cylinder block as shown in the illustration.
NOTICE: Do not apply engine oil to the bearing and its contact surface.
c. Install the lower bearing.
(1) Install the lower bearing to the bearing cap.
(2) Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 inch) or less
NOTICE: Do not apply engine oil to the bearing's contact area and backside.
d. Place the crankshaft on the cylinder block.
e. Lay a strip of Plastigage across each journal.
f. Examine the front marks and numbers and install the bearing caps on the cylinder block.
HINT: A number is marked on each main bearing cap to indicate the installation position.
g. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts.
h. Temporarily install the 16 main bearing cap bolts to the inside positions.
i. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 inch) by marking the 2 internal bearing cap bolts as a guide.
Bolt length: 100 to 102 mm (3.94 to 4.02 inch)
j. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
k. Apply a light coat of engine oil on the threads and under the head of 16 main bearing cap bolts.
l. Install the 16 main bearing cap bolts to the outside positions.
Bolt Length:
m. Install and uniformly tighten the 16 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm 45 ft. lbs.)
n. Mark the front side of the bearing cap bolts with paint.
o. Retighten the bearing cap bolts by 90° in the sequence shown.
p. Check that the painted mark is now at a 90° angle to the front.
NOTICE: Do not turn the crankshaft.
q. Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 26 Nm (265 kgf-cm 19 ft. lbs.)
Bolt (A) length: 45 mm (1.77 inch)
r. Remove the main bearing caps.
s. Measure the Plastigage at its widest point.
Standard oil clearance: 0.026 to 0.047 mm (0.0010 to 0.0019 inch)
Maximum clearance: 0.050 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
NOTICE: Completely remove the Plastigage after the measurement.
t. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table for the appropriate bearing number. There are 5 size of standard bearings, marked 1, 2, 3, 4 and 5 accordingly
Journal Bearings:
HINT: EXAMPLE: Cylinder block "11" + Crankshaft "06" Total number 17 (Use bearing "3")
Crankshaft Main Journal Diameter:
Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 Journal) (part 1):
Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 Journal) (part 2):
Standard Lower Bearing Center Thickness (No. 1 and No. 4 Journal):
Standard Upper Bearing Center Thickness (No. 2 and No. 3 Journal):
Standard Lower Bearing Center Thickness (No. 2 and No. 3 Journal):
42. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
Standard diameter: 10.8 to 11.0 mm (0.4252 to 0.4331 inch)
Minimum diameter: 10.7 mm (0.4213 inch)
If the diameter is less than the minimum, replace the bolt.