Cylinder Block Assembly: Testing and Inspection

CLEAN BLOCK
1. Using a suitable gasket scraper, remove all the gasket material from the cylinder block surface.
2. Using a suitable soft brush and solvent, thoroughly clean the cylinder block.





FLATNESS
1. Using precision straight edge and feeler gauge as shown in the illustration, measure the top surfaces of the cylinder block for warpage.
Maximum warpage: 0.070 mm (0.0028 inch).
2. If warpage is greater than maximum, replace the cylinder block.





VERTICAL SCRATCHES
1. Visually check the cylinder for vertical scratches.
2. If deep scratches are present, replace the cylinder block.





BORE DIAMETER
1. Using a suitable cylinder bore gauge, measure the cylinder diameter at positions A, B and C in the thrust and axial directions as shown in the illustration.
Standard diameter: 86.000-86.013 mm (3.3858-3.3863 inch).
Maximum diameter: 86.020 mm (3.3866 inch).
2. If the diameter is greater than maximum, replace the cylinder block.





REMOVE CYLINDER RIDGE
If the wear is less than 0.200 mm (0.008 inch), using a suitable ridge reamer, grind the top of the cylinder.





BEARING CAP BOLTS
1. Using suitable vernier calipers, measure the minimum diameter of the compressed thread at the measuring point shown in the illustration.
Standard diameter: 9.960-9.970 mm (0.3921-0.3925 inch).
Minimum diameter: 9.700 mm (0.3820 inch).
2. If the diameter is less than minimum, replace the bolt.