Cylinder Block

REMOVAL
Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate, oil pan and the oil pump case.

INSPECTION

Cylinder block
1. Visually check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects using a proper tool. Repair or replace the block if defective.





2. Measure the cylinder bore with a cylinder gauge at the three levels indicated in the directions of A and B.
Level 1: No.1 piston ring position with piston at TDC
Level 2: Center of cylinder
Level 3: Bottom of cylinder
3. It the cylinder bores show more than the specified out-of-round or taper, or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings should be installed.
Standard value
Cylinder bore: 93.00 - 93.03 mm (3.66 - 3.663 inch)
Deviation of concentricity and taper of cylinder bore: 0.02 mm (0.00079 inch) or less
4. If a ridge exists at the top of the cylinder, cut it away with a ridge reamer.
5. Oversize pistons are available in four sizes.
Oversize piston size.
0.25 O.S. 0.25 mm (0.01 inch)
0.50 O.S. 0.50 mm (0.02 inch)
0.75 O.S. 0.75 mm (0.03 inch)
1.00 O.S. 1.00 mm (0.039 inch)
6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize. When measuring the piston outside diameter measure the section of the thrust surface at 10 mm (3.5 inch) above the bottom of the piston skirt.
Clearance between piston and cylinder wall: 0.03 - 0.05 mm (0.001 - 0.002 inch)





7. Check the flatness of the upper surface. If the top surface exceeds limits, grind it to a minimum limit value or replace. (Measuring method is same as that of cylinder head flatness.)
Standard value
Flatness of the gasket mating surface: less than 0.05 mm (0.002 inch)
Limit
Flatness of the gasket mating surface: 0.1 mm (0.0039 inch)

Caution: When the cylinder head is assembled, grinding less than 0.2 mm is permissible. Grind the gasket surface of the cylinder block less than 0.2 mm.

Boring cylinder
1. Oversize pistons used should be determined on the basis of the largest bore cylinder.





Notice: Size mark is stamped on top of the piston.





2. Measure the outside diameter of the piston to be used.
3. Based on the measured O.D., calculate the boring finish dimension. Boring finish dimension = piston outer diameter + 0.02 - 0.04 mm (The clearance between piston outer diameter and cylinder) - 0.01 mm (Honing margin)
4. Bore each of the cylinders to the calculated size.

Caution: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order sequence.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard value: 0.01 - 0.03 mm (0.00039 - 0.0012 inch)

Notice:
1 6 cylinders should be bored to the same oversize.
2 Never bore only one cylinder to an oversize.

REASSEMBLY
1. Assemble the following parts by referring to their respective procedures.
1) Crankshaft
2) Drive plate
3) Piston
4) Cylinder head
5) Timing belt
6) Oil pump case