Part 2

ENGINE UNIT INSPECTION Continued





6. INSPECT PISTON RING SET
a. Inspect the piston ring groove clearance.
(1) 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.





b. Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) 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.





(3) 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.





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





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





8. INSPECT PISTON PIN OIL CLEARANCE
a. Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)
If the bushing inside diameter is not as specified, check the oil clearance.
(2) 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: 0.05 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and piston pin with a new piston and pin set.





9. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion of the connecting rod bolt.
Standard diameter: 7.200 to 7.300 mm (0.2835 to 0.2874 inch)
Maximum diameter: 7.00 mm (0.2756 inch)
If the diameter is less than the minimum, replace the bolt.





10. INSPECT CRANKSHAFT BEARING CAP BOLT
a. Using a vernier caliper, measure the tension portion diameter of the main bearing cap bolt.
Standard diameter: 7.500 to 7.600 mm (0.2953 to 0.2992 inch)
Maximum diameter: 7.20 mm (0.2835 inch)
If the diameter is less than the minimum, replace the cap bolt.





11. INSPECT CRANKSHAFT
a. Inspect for circle runout.
(1) Place the crankshaft on V-blocks.
(2) 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 the maximum, replace the crankshaft.





b. Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter: 66.988 to 67.000 mm (2.6373 to 2.6378 inch)
Crank pin diameter: 51.982 to 52.000 mm (2.0465 to 2.0472 inch)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) Check each main journal and 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.