Cylinder Block Assembly: Testing and Inspection

1. Using a suitable gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Thoroughly clean the cylinder block.

CAUTION: Washing the cylinder block at temperatures above 45° C, may cause the cylinder liner to stick out beyond the cylinder block, always wash the cylinder block at a temperature of 45° C or less.





3. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.07 mm (0.0028 inch).
If warpage is greater than maximum, replace the cylinder block.





4. Visually check the cylinder bores for vertical scratches.
If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter as follows:






NOTE:
- There are three sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.
- Refer to the illustration for mark location.






6. Using a suitable cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter:
Cylinders with bore mark "1": 87.500-87.510 mm (3.4449-3.4453 inch).
Cylinders with bore mark "2": 87.510-87.520 mm (3.4453-3.4457 inch).
Cylinders with bore mark "3": 87.520-87.530 mm (3.4457-3.4461 inch).
Maximum diameter: 87.73 mm (3.4539 inch).
If the diameter is greater than maximum, replace the cylinder block.





7. Remove cylinder ridge if the wear is less than 0.2 mm (0.008 inch), using a ridge reamer.





8. Using vernier calipers, measure the tension portion diameter of the main bearing cap stud bolt.
Standard diameter: 7.500-7.600 mm (0.2953-0.2992 inch).
Minimum diameter: 7.40 mm (0.2913 inch).
If the diameter is less than minimum, replace the stud bolt.