Cylinder Block Assembly: Testing and Inspection

VISUAL INSPECTION
Visually check the cylinder block for scores, rust and corrosion, cracks or any other defects. Repair or replace the block if defective.

CYLINDER BORE






Measure the cylinder bore with a cylinder gauge at the three levels indicated in the directions of A and B as shown in the illustration.
Level 1: No.1 piston ring position with piston at TDC.
Level 2: Center of cylinder.
Level 3: Bottom of cylinder.

If the cylinder bores show more than the specified out-of round or taper, or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings should be installed.
Cylinder bore:
Standard Value; 91.10-91.14mm (3.5866-3.5882 inch).
Piston to cylinder wall clearance:
Standard Value; 0.02-0.04 mm (0.0008-0.0016 inch).

NOTE: The standard measurement of the piston outside diameter is taken at a level 12mm (0.47 inch) above the bottom of the piston skirt and across the thrust faces.

Out of roundness and taper of cylinder bore.
Maximum allowable; 0.02mm (0.0008 inch).

CYLINDER HEAD GASKET SURFACES






Check the top surface of the cylinder block for flatness as shown in the illustration. If the top surface exceeds limits, grind to the minimum limit or replace.
Flatness of cylinder head surface:
Standard value; 0.05 mm (0.0020 inch).
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