Cylinder Block Assembly: Testing and Inspection

Measure Cylinder
- Measure cleaned cylinder bores with a hole gauge at the 3 measuring points (1, 2, 3) in longitudinal and transverse direction

Bore Cylinder Bores
- When performing repairs, the cylinder bores should be machined to correspond to die group letters of the new-pistons.
Refer to Specifications of Cylinder Bore below.
- The group code letters are inscribed the piston crown
1st repair size
2nd repair size
- Chamfer cylinder bores after boring

Chamfering Cylinder Bores (Part 1 Of 2):

Chamfering Cylinder Bores (Part 2 Of 2):

Chamfer Cylinder Bores
- After boring cylinder bores, chamfer with a suitable tool as shown in the illustration.
- Smooth the bottom of the chamfer with a polishing stone.

Hone Cylinder Bores
- Honing Angle: 50°±10°
- Basic peak-to-valley height (R3z) after final honing and brushing
Refer to Specifications of Cylinder Bore below.


Specifications Of Cylinder Bore
- Cylinder Diameter
Standard size: 89.900 mm
Group code letter A:89.900 - 89.906 mm
Group code letter X:89.907 - 89.912 mm
Group code letter B:89.913 - 89.918 mm
1st repair size: 90.15
Group code letter A:90.150 - 90.156
Group code letter X:90.157 - 90.162
Group code letter B:90.163 - 90.168
2nd repair size: 90.400 mm
Group code letter A: 90.400 - 90.406 mm
Group code letter X: 90.407 - 90.412 mm
Group code letter B: 90.413 - 90.418 mm
- Cylinder bore
Wear limit in longitudinal and transverse direction: 0.10 mm
Permissible Difference From Cylinder Shape:
When New: 0.007 mm
Wear Limit: 0.050 mm
Permissible Difference From Rectangularity Related To Cylinder Height: 0.050 mm
Surface Finish:
Basic peak to Valley Height (R3z) After Final Honing: 0.002 - 0.005 mm
Maximum Peak To Valley Height: 0.011 mm
Honing Angle: 50° ± 10°