Cylinder Block Assembly: Testing and Inspection

DISASSEMBLY
Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate, oil pan, and oil pump case.

INSPECTION
Cylinder Block





1. Visually check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Repair or replace the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated in the 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

3. 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: 91.10 - 91.14mm (3.5866 - 3.5882)
Out of roundness and taper of cylinder bore: Max 0.02mm (0.0008in)

4. If a ridge exists at the top of the cylinder, cut it away with a ridge reamer.
5. Oversize pistons are available in four sizes.

Piston service size and mark mm(in):
0.25 (0.010) O.S: 0.25
0.50 (0.020) O.S: 0.50
0.75 (0.030) O.S: 0.75
1.00 (0.033) O.S: 1.00

6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize. 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.

Piston-to-cylinder wall clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)





7. Check for damage or cracks in the cylinders.
8. Check the top surface of the cylinder block for flatness. If the top surface exceeds limits, grind to the minimum limit or replace.

Standard value:
Flatness of cylinder head surface:
Maximum: 0.05 mm (0.0020 inch)
Limit: 0.10 mm ( 0.0033 inch)

CAUTION: When the cylinder head is assembled, grinding less than 0.2mm (0.008inch) is permissible.

Boring Cylinder





1. Oversize pistons used should be determined based on the largest bore cylinder.

NOTE: Size mark is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.
3. Based on the measured O.D., calculate the boring finish dimension.

Boring finish dimension = Piston O.D + 0.02 to 0.04 mm (0.0008 to 0.0016 inch) (clearance between piston and cylinders - 0.02 mm (0.008 inch) (honing margin inch)

4. Bore each of the cylinders to the calculated size.

CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order sequence.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.001 6 inch)

NOTE: When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to an oversize.

REASSEMBLY
1. Install the following parts:
- Crankshaft
- Drive plate
- Piston
- Cylinder head
- Timing belt
- Oil pump case