Cylinder Block Assembly: Testing and Inspection

1. Remove gasket material.



Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.

CAUTION: 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.

3. 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.
Max. warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.

4. Inspect cylinder for vertical scratches.



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

5. 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.
Std. diameter: 87.500 - 87.512 mm (3.4449 - 3.4453 inch)
Max. diameter: 87.52 mm (3.4457 inch)
If the diameter is greater than maximum, replace the cylinder block.




6. Remove cylinder ridge.
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.

7. Inspect 12 pointed head main bearing cap bolts.



Using vernier calipers, measure the tension portion diameter of the bolt.
Std. diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 inch)
Min. diameter: 7.20 mm (0.2835 inch)
If the diameter is less than minimum, replace the bolt.

8. Clean piston.
9. Inspect piston oil clearance.
10. Inspect piston ring groove clearance.
11. Inspect piston ring end gap.
12. Inspect piston pin fit.



At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.
13. Inspect connecting rod alignment.
14. Inspect piston pin oil clearance.
15. If necessary, replace connecting rod bushing.
16. Inspect connecting rod bolts.



Using vernier calipers, measure the tension portion diameter of the bolt.
Std. diameter: 7.2 - 7.3 mm (0.284 - 0.287 inch)
Min. diameter: 7.0 mm (0.276 inch)
If the diameter is less than minimum, replace the bolt.

17. Inspect crankshaft for circle runout.



(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout, as shown in the illustration.
Max. circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than maximum, replace the crankshaft.

18. Inspect main journals and crank pins.



(a) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter: 60.988 - 61.000 mm (2.4011 - 2.4016 inch)
Crank pin diameter: 52.992 - 53.000 mm (2.0862 - 2.0866 inch)
If the diameter is not as specified, check the oil clearance.
If necessary, replace the crankshaft.
(b) Check each main journal and crank pin for taper and out-of-round as shown.
Max. taper and out-of-round: 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than maximum, replace the crankshaft.

19. Replace front crankshaft seal.
20. Replace crankshaft main bearing seal.