Inspection

INSPECTION





1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block.
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, so always wash the cylinder block at a temperature of 45°C (113°F) or less.





3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

Maximum warpage: 0.07 mm (0.0028 inch)

If warpage is greater than maximum, replace the cylinder block.





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





5. Inspect cylinder bore diameter.
Using a cylinder gauge, measure the cylinder bore diameter, positions A, B and C in the thrust: and axial directions.

Standard diameter: 87.500 - 87.512 mm (3.4449 - 3.4453 inch)
Maximum diameter: 87.52 mm (3.4457 inch)

If the diameter is greater than maximum, replace the cylinder block.





6. 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.





7. Inspect 12 pointed head main bearing cap bolts.
Using vernier calipers, measure the tension portion diameter of the bolt.

Standard diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 inch)
Minimum diameter: 7.20 mm (0.2835 inch)

If the diameter is less than minimum, replace the bolt.





8. 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.

9. Inspect piston oil clearance.





a. AISIN made:
1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 23.2 mm (0.913 inch) from the piston head.

Piston diameter: 87.406 - 87.416 mm (3.4412 - 3.4416 inch)

2) Measure the cylinder bore diameter in the thrust directions. (See inspection)
3) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance: 0.084 - 0.106 mm (0.0033 - 0.0042 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)

If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.

HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".





b. MAHLE made:
1) Using a micrometer, measure the piston diameter a" right angles to the piston pin center line, 41.2 mm (1.622 inch) from the piston head.

Piston diameter: 87.453 - 87.467 mm (3.4430 - 3.4436 inch)

2) Measure the cylinder bore diameter in the thrust directions. (See inspection)
3) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance: 0.033 - 0.059 mm (0.0013 - 0.0023 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)

If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.

HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".





10. Inspect piston ring groove clearance.
Using a feeler gauge, measure the clearance between new piston right and the wall of the ring groove.

Ring groove clearance:
No.1: 0.020 - 0.070 mm (0.0008 - 0.0028 inch)
No.2: 0.020 - 0.060 mm (0.0008 - 0.0024 inch)

If the clearance is not as specified, replace the piston.
11. 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 bot tom of the ring travel, 105 mm (4.13 inch) from the top of the cylinder block.





c. Using a feeler gauge, measure the end gap.

Standard end gap:
No.1: 0.25 - 0.35 mm (0.0098 - 0.0138 inch)
No.2: 0.35 - 0.45 mm (0.0138 - 0.0177 inch)
Oil (Side rail): 0.15 - 0.40 mm (0.0059 - 0.0157 inch)

Maximum end gap:
No.1: 0.95 mm (0.0374 inch)
No.2: 1.05 mm (0.0413 inch)
Oil (Side rail): 1.00 mm (0.0394 inch)

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.





12. Inspect piston pin fit.
At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.
13. Inspect connecting rod alignment.
Using a rod aligner and feeler gauge, check the connecting rod alignment.





- Check for bend.

Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)

If bend 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.





14. 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 bushing inside 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.
15. If necessary, replace connecting rod bushing.





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





b. Align the oil holes of a new bushing and the connecting rod.
c. Using (SST) and a press, press in the bushing.





d. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step 14) between the bushing and piston pin.





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





16. Inspect connecting rod bolts.
Using vernier calipers, measure the tension portion diameter of the bolt.

Standard diameter: 7.2 - 7.3 mm (0.284 - 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)

If the diameter is less than minimum, replace the bolt.





17. Inspect crankshaft for circle runout.
a. Place the crankshaft on V-blocks.
b. Using a dial indicator, measure the circle runout, as shown in the illustration.

Maximum circle runout: 0.06 mm (0.0024 inch)

If the circle runout is greater than maximum, replace the crankshaft.





18. Inspect main journals and crank pins.
a. Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter: 60.988 - 61.000 mm (2.4011 - 2.4016 inch)
Crank pin diameter: 52.992 - 53.000 mm (2.0862 - 2.0866 inch)

If the diameter is not as specified, check the oil clearance.
If necessary, replace the crankshaft.
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 and out-of-round is greater than maximum, replace the crankshaft.


REPLACEMENT
1. Replace crankshaft front oil seal.

HINT: There are 2 methods (A and B) to replace the oil seal which are as follows:

a. If the oil pump is removed from the cylinder block:





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





2) Using Special Service Tool (SST) 09223 - 00010 or equivalent, and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
3) Apply MP grease to the oil seal lip.
b. If the oil pump is installed to the cylinder block:





1) Using a knife,cut off the oil seal lip.
2) Using a screwdriver, ply 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.
2. Replace crankshaft rear oil seal.

HINT: There are 2 methods to replace the oil seal witch are as follows:

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

3) Apply UP 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.