Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6) (RH Side):

COMPONENTS (Part 7) (LH Side):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

INSPECTION Continued

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 mm (0.0059 to 0.0157 in.)
Maximum thrust clearance: 0.50 mm (0.020 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod assemblies. 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 (Procedure "A").

HINT: The matchmarks on the connecting rods and caps are provided to ensure correct reassembly.

(b) Using SST, remove the 2 connecting rod cap bolts (Procedure "B").

(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 (Procedure "C").

HINT: Keep the lower bearing inserted to the connecting rod cap.

(d) Clean the crank pin and bearing (Procedure "D").
(e) Check the crank pin and bearing for pitting and scratches (Procedure "E").

(f) Lay a strip of Plastigage on the crank pin (Procedure "F").

(g) Check that the front mark of the connecting rod cap is facing forward (Procedure "G").

(h) Using SST, install the connecting rod cap (Procedure "H").

NOTICE: Do not turn the crankshaft.

(i) Remove the 2 bolts and connecting rod cap (see procedure "B" and "C" above).

(j) Measure the Plastigage at its widest point.
Standard oil clearance: 0.045 to 0.067 mm (0.0018 to 0.0026 in.)
Maximum oil clearance: 0.070 mm (0.0028 in.)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

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 mark 1, 2, 3 or 4 on its surface.

Reference: Connecting rod diameter:

Standard bearing center wall thickness:

Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
(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 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
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 in.)

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 in.)
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 6 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: 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter: 94.200 mm (3.7087 in.)
If the diameter is greater than the maximum, replace the cylinder block.

33. INSPECT PISTON SUB-ASSEMBLY WITH PIN
(a) Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end as specified.
Distance: 9.8 mm (0.3858 in.)
Standard diameter: 93.960 to 93.980 mm (3.6992 to 3.7000 in.)
Maximum diameter: 93.830 mm (3.6941 in.)

34. INSPECT PISTON OIL CLEARANCE
(a) Measure the cylinder bore diameter in the thrust direction.
(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.02 to 0.052 mm (0.0008 to 0.0020 in.)
Maximum oil clearance: 0.06 mm (0.0024 in.)
If the oil clearance is greater than the maximum, 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 in.) from the top of the cylinder block.

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.