Cylinder Block

CYLINDER BLOCK INSPECTION AND REPAIR
1. CLEAN CYLINDER BLOCK
A. Remove gasket material
Using a gasket scraper. remove all the gasket material from the top surface of the cylinder block.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.

NOTICE: 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.






2. 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 in.)
If warpage is greater than maximum, replace the cylinder block.






3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches. If deep scratches are present. replace the cylinder block.






4. 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 in.)
Maximum diameter: 87.52 mm (3.4457 in.)
If the diameter is greater than maximum, replace the cylinder block.






5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.). using a ridge reamer. grind the top of the cylinder.






6. 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 in.)
Minimum diameter: 7.20 mm (0.2835 in.)
If the diameter is less than minimum. replace the bolt.