Cylinder Block
Cylinder block1. Check cylinder block for following conditions and repair or replace cylinder block as needed.
a. Leakage damage
b. Cracks
c. Scoring of cylinders
2. Check distortion of cylinder head mating surface (block deck) in six directions shown in figure.
Distortion: 0.006 inch (0.15 mm) maximum
3. Repair block deck by surface grinding block, or in extreme cases replace cylinder block.
Maximum resurface amount: 0.008 inch (0.20 mm)
4. If deck is at or below this specification, replace cylinder block.
Notice: Before surfacing cylinder block, check deck height from center line of crankshaft to deck surface.
5. Measure cylinder bore with a dial bore gauge at X and Y vectors shown in figure.
Cylinder bore size
Standard: 3.1892 - 3.1897 inch (81.006 - 81.019 mm)
Bore + 0.010 inch (0.25 mm): 3.1990 - 3.1996 inch (81.256 - 81.269 mm)
Bore + 0.020 inch (0.50 mm): 3.2089 - 3.2094 inch (81.506 - 81.519 mm)
6. Take cylinder measurements at top, center and bottom of cylinder to check for cylinder diameter, taper and out-of-round.
Taper: 0.0007 inch (0.019 mm) Maximum
Out-of-round: 0.0007 inch (0.019 mm) Maximum
Notice: Boring cylinders should be based on maximum oversized piston that can be installed without exceeding maximum overbore.