Cylinder Block Assembly: Service and Repair
CYLINDER BLOCKDISASSEMBLY AND REASSEMBLY
Disassembly And Reassembly:
INSPECTION
NOTE:
1. Clean pants to remove dust. oil, carbon deposits. and scale before starting the inspection and repair procedure.
2. Check cylinder block for water leaks and damage before cleaning.
3. Remove deposits from oil holes and make sure that they are not clogged.
4. Keep pants neatly arranged according to a matched pair.
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace.
2. Using a straightedge and feeler gauge. check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.0020 in.) or less
Limit: 0.1 mm (0.0040 in.)
3. If the distortion is excessive, correct within the allowable limit or replace.
Grinding limit: 0.2 mm (0.008 in.)
The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head is 0.2 mm (0.008 in.) at maximum.
Cylinder block height (when new): 284 mm (11.18 in.)
4. Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace.
5. Using cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct cylinder to an oversize and replace piston and piston rings. Measure at the points shown in illustration.
Standard value:
Cylinder l.D.: 85.00-85.03 mm (3.3465-3.3476 in.)
Out-of-roundness and taper of cylinder bore: 0.01 mm (0.0004 in.) or less
CYLINDER REBORING
1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder.
NOTE: Size mark is stamped on piston top.
2. Measure outside diameter of piston to be used. Measure it in thrust direction as shown.
3. Based on measure piston O.D. calculate boring finish dimension.
Boring finish dimension = Piston 0.D. + (clearance between piston 0.0. and cylinder) -0.02 mm (0.0008 in.) (honing margin)
4. Bore all cylinders to calculated boring finish dimension.
CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No.2 to No.4 to No.1 to No.3.
5. Hone to final finish dimension (piston O.D. + clearance between piston O.D. and cylinder).
6. Check clearance between piston and cylinder.
Clearance between piston and cylinder:
(Non-Turbo): 0.02-0.04 mm (0.0008-0.0016 in.)
(Turbo): 0.03-0.05 mm (0.0012-0.0020 in.)
NOTE: When boring cylinders, finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize.