Part 1

ENGINE UNIT

INSPECTION
1. INSPECT CAMSHAFT
2. INSPECT NO.3 CAMSHAFT SUB-ASSEMBLY
3. INSPECT CYLINDER HEAD SUB-ASSEMBLY





4. INSPECT CYLINDER BLOCK SUB-ASSEMBLY
a. Clean the cylinder block.
(1) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
(2) 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. Always wash the cylinder block at a temperature of 45°C (113°F) or less.





b. Inspect for flatness.
(1) Using a precision straightedge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than the maximum, replace the cylinder block.





c. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.





d. Inspect the cylinder bore diameter.

HINT: There are 3 sizes of the standard cylinder bore diameter, marked 1, 2 and 3 accordingly. The mark is stamped on the top of the cylinder block.

If deep scratches are present, replace the cylinder block.





(1) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

Standard Diameter:

Maximum diameter: 91.149 mm (3.5885 inch)
If the average of the diameter is greater than the maximum, replace the cylinder block.





HINT: If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.





5. INSPECT WITH PIN PISTON SUB-ASSEMBLY
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 standard diameter sizes, marked 1, 2 and 3. 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, 28.1 mm (1.106 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: 0.060 to 0.101 mm (0.0023 to 0.0040 inch)
Maximum oil clearance: 0.121 mm (0.0048 inch)
If the oil clearance is greater than the maximum, replace all the 8 pistons. 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 3L and the RH piston is marked with 3R.





c. Inspect the piston pin fit.
(1) At 60°C (140°F), check that the piston pin can be pushed 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)