Cylinder Block Assembly: Testing and Inspection

1. Clean cylinder block.





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





2. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 inch)
If warpage is greater than maximum, replace the cylinder block.
3. Inspect cylinder for vertical scratches.
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.
4. Inspect cylinder bore diameter.





NOTE: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.





Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter:
STD
Mark "1": 81.000 - 81.010 mm (3.1890 - 3.1894 inch)
Mark "2": 81.010 - 81.020 mm (3.1894 - 3.1898 inch)
Mark "3": 81.020 - 81.030 mm (3.1898 - 3.1902 inch)
Maximum diameter:
STD: 81.23 mm (3.1982 inch)
O/S 0.50: 81.73 mm (3.2177 inch)
If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.





5. 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.