Cylinder Block Assembly: Testing and Inspection
CYLINDER BLOCK INSPECTION1. 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 thickness 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 6 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": 100.000 - 100.010 mm (3.9370 - 3.9374 inch)
Mark "2": 100.010 - 100.020 mm (3.9374 - 3.9378 inch)
Mark "3": 100.020 - 100.030 mm (3.9378 - 3.9382 inch)
Maximum diameter:
STD: 100.23 mm (3.9461 inch)
O/S 0.50: 100.73 mm (3.9658 inch)
O/S 1.00: 101.23 mm (3.9854 inch)
If the diameter is greater than maximum, rebore all the 6 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.
6. Inspect main bearing cap bolts.
Using vernier calipers, measure the thread outside diameter of the bolt.
Standard outside diameter: 10.85 - 11.00 mm (0.4271 - 0.4331 inch)
Minimum outside diameter: 10.6 mm (0.417 inch)
If the diameter is less than minimum, replace the bolt.
7. Inspect cylinder block orifice.
Check the orifice for clogging.
If necessary, replace the orifice.
8. Inspect bearing of oil pump drive shaft gear.
Check the bearing for pitting and scratches.
If the bearing is damaged, replace the cylinder block.