Cylinder Block Assembly: Testing and Inspection

CYLINDER BLOCK INSPECTION



1. Using a suitable gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Thoroughly clean the cylinder block.

CAUTION: Washing the cylinder block at temperatures above 45°C, may cause the cylinder liner to stick out beyond the cylinder block, always wash the cylinder block at a temperature of 45°C or less.




3. 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.




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

5. Inspect cylinder bore diameter as follows:




NOTE:
- There are three sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.
- Refer to the illustration for mark location.




6. Using a suitable cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

Standard diameter:
Bore mark "1": 87.50 - 87.51 mm (3.4449 - 3.4453 in).
Bore mark "2": 87.51 - 87.52 mm (3.4453 - 3.4457 in).
Bore mark "3": 87.52 - 87.53 mm (3.4457 - 3.4461 in).

Maximum diameter: 87.73 mm (3.4539 in).

If the diameter is greater than maximum, replace the cylinder block.




7. Remove cylinder ridge using a ridge reamer if the wear is less than 0.2 mm (0.008 in).




8. Using vernier calipers, measure the tension portion diameter of the main bearing cap stud bolt.
Standard diameter: 7.50 - 7.60 mm (0.2953 - 0.2992 in).
Minimum diameter: 7.40 mm (0.2913 in).
If the diameter is less than minimum, replace the stud bolt.