Cylinder Block: Replacement

HINT:

• Bore all the 8 cylinders to the oversized piston outside diameter.
• Replace all the piston rings with the ones to match the oversized pistons.

1. Keep 8 new O/S pistons.
   1. O/S 0.50 piston diameter: 94.402 - 94.430 mm (3.7166 - 3.7177 in.)

   HINT:

   The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R".

2. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head.
Fig 1: Measuring Piston Diameter At Right Angles To Piston Pin Center Line Using Micrometer
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3. Calculate the amount for each cylinder to be rebored as follows:

   Size to be rebored = P + C - H

   P = Piston diameter

   1. C = Piston clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.)
   2. H = Allowance for honing: 0.02 mm (0.0008 in.) or less
4. Bore and hone the cylinders to calculated dimensions.
   1. Maximum honing: 0.02 mm (0.0008 in.)

1. Using SST and a press, press out the bushing.
   1. SST 09222-30010
   Fig 2: Pressing Out Bushing Using SST

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2. Align the oil holes of a new bushing and the connecting rod.
Fig 3: Locating Oil Holes
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3. Using SST and a press, press in the bushing.
   1. SST 09222-30010
4. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See INSPECTION ) between the bushing and piston pin.
   Fig 4: Honing Bushing Using Pin Hole Grinder

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5. 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.
Fig 5: Checking Piston Pin Fit
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HINT:

There are 2 methods ( a and  b) to replace the oil seal.

1. If the oil pump is removed from the cylinder block:
   1. Using a screwdriver, pry out the oil seal.
      Fig 6: Prying Out Crankshaft Front Oil Seal

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   2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
      Fig 7: Tapping In Oil Seal Using SST & Hammer

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      1. SST 09316-60011 (09316-00011)
   3. Apply MP grease to the oil seal lip.
2. If the oil pump is installed to the cylinder block:
   1. Using a knife, cut off the oil seal lip.
   2. Using a screwdriver, pry out the oil seal.
      Fig 8: Prying Out Oil Seal Using Screwdriver

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