Cylinder Block Assembly: Testing and Inspection

CYLINDER BLOCK
Visually check the engine block for scores, rust and corrosion.
Check for cracks or any other defects.
Repair or replace the block if defective.

CYLINDER BORE
1. Measure cylinder bore with a cylinder gauge at three levels in directions of A and B.
Level 1: No. 1 piston ring position with piston at TDC
Level 2 :Center of cylinder
Level 3 :Bottom of cylinder
2. If cylinder bores show more than specified out-of-round or taper, or if cylinder walls are badly scuffed or scored, rebore and hone engine block, and fit with new, oversize piston and rings.
Standard values:
Cylinder bore:
85.00-85.03 mm (3.3465-3.3476 inch)
Out-of-roundness and taper of cylinder bore:
Max. 0.01 mm (0.0004 inch)
3. If cylinder top ridge is worn in stages, cut away with ridge reamer.

CYLINDER BLOCK HEAD GASKET SURFACE






Check top surface for flatness. If excessive warping is evident, grind to minimum limit or replace engine block.
Standard value:
Flatness of cylinder block surface Max.
0.05 mm (0.0020 inch)
Engine block (New) height
284 mm (11.1800 inch)
Wear Limit:
Flatness of cylinder block surface
0.10 mm (0.0039 inch)
Overall height
283.80 mm (11.1721 inch)

NOTE: The cylinder block surface should be ground to within - 0.2 mm (-0.0079 inch) even with the grind of cylinder head surface.