Cylinder Block Assembly: Testing and Inspection

1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.

CAUTION: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45° C (113° F) or less.





3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.





4. Inspect cylinder for vertical scratches.
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.





5. Inspect cylinder bore diameter.
Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 87.500 - 87.512 mm (3.4449 - 3.4453 inch)
Maximum diameter: 87.52 mm (3.4457 inch)
If the diameter is greater than maximum, replace the cylinder block.





6. Remove cylinder ridge.
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.





7. Inspect 12 pointed head main bearing cap bolts.
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 inch)
Minimum diameter: 7.20 mm (0.2835 inch)
If the diameter is less than minimum, replace the bolt.