Part 2
ENGINE UNITCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
INSPECTION(continued)
25. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the valve guide bush.
Inside diameter: 5.51 to 5.53 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement (Step 8) from the valve guide bush inside diameter measurement.
Standard overall length:
Minimum overall length:
If the oil clearance is greater than the maximum, replace the valve and valve guide bush.
26. REMOVE VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).
(b) Place the cylinder head on a wooden block.
(c) Using SST, tap out the valve guide bush.
SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)
27. INSTALL VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Bush bore diameter: 10.295 to 10.315 mm (0.4053 to 0.4061 in.)
If the bush bore diameter of the cylinder head is greater than 10.315 mm (0.4061 in.), machine the bush bore to the dimension of 10.345 to 10.365 mm (0.4073 to 0.4081 in.).
Valve guide bush diameter:
(b) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).
(c) Place the cylinder head on a wooden block.
(d) Using SST, tap in a new valve guide bush to the specified protrusion height.
SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)
Protrusion height: 9.3 to 9.7 mm (0.366 to 0.382 in.)
(e) Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem.
Standard overall length:
28. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the valve lifter diameter.
Valve lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
29. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(b) Subtract the valve lifter diameter measurement (Step 16) from the lifter bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum, replace the valve lifter.
If necessary, replace the cylinder head.
30. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the camshaft bearing caps, camshaft bearings and camshaft journals.
(b) Install the camshaft bearing.
(c) Place the camshaft on the cylinder head.
(d) Lay a strip of Plastigage across each of the camshaft journals.
(e) Install the camshaft bearing caps.
NOTICE: Do not turn the camshafts.
(f) Remove the camshaft bearing caps.
(g) Measure the Plastigage at its widest point.
Standard oil clearance (Cylinder head RH):
Standard oil clearance (Cylinder head LH):
Maximum oil clearance (Cylinder head RH):
Maximum oil clearance (Cylinder head LH): 0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the camshaft bearings and/or camshaft.
If necessary, replace the camshaft bearing caps and cylinder head together.
Reference:
(h) Remove the Plastigage completely.
(i) Remove the camshafts.
(j) Remove the camshaft bearing.
31. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts.
(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.04 to 0.09 mm (0.0016 to 0.0035 in.)
Maximum thrust clearance: 0.11 mm (0.0043 in.)
If the thrust clearance is greater than the maximum, replace the camshafts.
If necessary, replace the camshaft bearing caps and cylinder head as a set.
32. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than the maximum, replace the cylinder block.
33. 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: 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter: 94.132 mm (3.7060 in.)
If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.
34. INSPECT WITH PIN PISTON SUB-ASSEMBLY
(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 in.) from the piston head.
Piston diameter: 93.910 to 93.920 mm (3.6972 to 3.6976 in.)
35. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.080 to 0.102 mm (0.0031 to 0.0040 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
36. 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 in.) per 100 mm (3.94 in.)
If misalignment is greater than the maximum, replace the connecting rod assembly.
(2) Check twist.
Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than the maximum, replace the connecting rod assembly.
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: 22.001 to 22.010 mm (0.8662 to 0.8665 in.)
HINT: Piston pin hole inside diameter
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.)
HINT: Piston pin diameter
(c) 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 in.)
HINT: Bushing inside diameter
(d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.)
Maximum oil clearance: 0.040 mm (0.0016 in.)
(e) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and piston pin together.
(f) 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 in.)
Maximum oil clearance: 0.050 mm (0.0020 in.)
(g) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together.
38. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bushing.
SST 09222-30010
39. INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil holes of a new bushing and the connecting rod.
(b) Using SST and a press, press in the bushing.
SST 09222-30010
(c) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
HINT: Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.
40. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.
Ring groove clearance:
No. 1: 0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil: 0.07 to 0.15 mm (0.0028 to 0.0060 in.)
41. 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 in.) from the top of the cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1: 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2: 0.40 to 0.50 mm (0.0157 to 0.0197 in.)
Oil (Side rail): 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum end gap:
No. 1: 1.0 mm (0.039 in.)
No. 2: 1.1 mm (0.043 in.)
Oil (Side rail): 1.0 mm (0.039 in.)
42. 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 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
43. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 10.0 to 10.2 mm (0.393 to 0.402 in.)
If the diameter is less than the minimum, replace the bolt.
44. 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 in.)
(b) Using a micrometer, measure the diameter of each main journal.
Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
(c) Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
(d) Using a micrometer, measure the diameter of each crank pin.
Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
(e) Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
45. INSPECT CRANKSHAFT OIL CLEARANCE
HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
(a) Clean each main journal and bearing.
(b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
(c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 bottom bearings.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
HINT: A number marked on each main bearing cap indicates the installation position.
(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.
(g) Apply a light coat of engine oil to the threads of the bearing cap bolts.
(h) Temporarily install the 8 main bearing cap bolts to the inside positions.
(i) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.).
(j) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(k) Apply a light coat of engine oil to the threads of the main bearing cap bolts.
(l) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 61 Nm (622 kgf/cm, 45 ft. lbs.)
(m) Mark the front side of the bearing cap bolts with paint.
(n) Retighten the bearing cap bolts 90° in the sequence as shown.
(o) Check that the painted mark is now at a 90° angle to the front.
NOTICE: Do not turn the crankshaft.
(p) Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 26 Nm (262 kgf/cm, 19 ft. lbs.)
(q) Remove the main bearing caps.
(r) Measure the Plastigage at its widest point.
Standard oil clearance: 0.018 to 0.030 mm (0.0007 to 0.0012 in.)
Maximum clearance: 0.046 mm (0.0018 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
NOTICE: Completely remove the Plastigage.
(s) If replacing a bearing, replace it with one that has 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 appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.
Journal bearings:
HINT:
EXAMPLE
Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3")
Part 1:
Part 2:
