Cylinder Block Assembly: Testing and Inspection

INSPECTION





1. Measure wear and taper in direction X and Y at three levels in each cylinder as shown.
- If the measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the block.
- If the block is to be rebored, refer to Piston, Engine / Testing and Inspection for Clearance Inspection after reboring.

NOTE: Scored or scratched cylinder bores must be honed.





2. Check the top of the block for warpage. Measure along the edges and across the center as shown.





Engine Block Warpage
Standard (New): below 0.07 mm (0.003 inch) max.
Service Limit: 0.10 mm (0.004 inch)

BORE HONING

CAUTION: This cylinder liner uses FRM (Fiber Reinforced Metal). Hone only as directed below.

1. Measure the cylinder bores.
If the block is to be reused, hone the cylinders and remeasure the bores.





2. To hone the cylinder bores:
- Use only a rigid hone.
- Honing stone: GC-600-J or finer stone (for nonferrous metals)
- Pressure: 200 - 300 kPa (2 - 3 kgf/cm2, 28 - 43 psi)
- Honing rpm: 45 - 50 rpm
- Honing thickness: Less than 0.02 mm (0.0008 inch) Do not hone more than 20 cycles
- Honing lubricant: Oil type
- Honing pattern: 60 degree cross-hatch

CAUTION: Clean the honing stone every 5 cycles.

3. When honing is complete, thoroughly clean the cylinder block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil immediately to prevent rusting.

NOTE: Never use solvent, it will only redistribute the grit on the cylinder walls.





4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the cylinder block.

NOTE: Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.