Engine Block Clean and Inspect

1. Clean all gasket surfaces, the oil passages, the coolant passages and the engine block with solvent.
2. Inspect the cylinder block for cracks in the cylinder walls, the coolant jackets and the crankshaft bearing webs.
3. If cracks are found, the cylinder block must be replaced.
4. Measure the cylinder bore diameter at 20 mm (1), 50 mm (2), and 60 mm (3) from the deck face. The cylinder bore diameter specification is 86.992 - 87.008 mm (3.424 - 3.425 inch).
5. Measure the cylinder bores for taper along the thrust surfaces (perpendicular to the crankshaft centerline) using the following procedure:
5.1. Measure the cylinder diameter 5 mm below the deck surface.
5.2. Measure the cylinder diameter 102 mm below the deck surface.
5.3. Calculate the difference between the measurements at 102 mm and 5 mm. The result will be the cylinder taper.
6. Measure the cylinder bores for out-of-round using the following procedure:
6.1. Measure both the thrust and non-thrust cylinder diameter 5 mm below the deck. Record your measurements.
6.2. Calculate the difference between the two measurements. The result will indicate out-of-round at the upper end of the cylinder.
6.3. Measure both the thrust and non-thrust cylinder diameter at 102 mm below the deck surface. Record your measurements.
6.4. Calculate the difference between the two measurements. The result will indicate out-of-round at the lower end of the cylinder.
7. Specifications for cylinder out-of-round and taper are as follows:
^ Production: 0.010 mm (0.0004 inch)
^ Maximum: 0.100 mm (0.004 inch)
8. If the cylinders exceed these specifications, replace the cylinder block because there are no oversized pistons and rings available for service.