Cylinder Block Inspection

1. Remove gasket material using a gasket scraper, Scotch Brite Pads and Disk (3M Clean' N Strip 2 inch D x 1/2 inch W x 1/4 inch center hole) remove all the gasket material from the cylinder block, oil pan, rear seal carrier, and front cover surfaces.
a. The oil pan, front cover, and rear seal carrier bolt holes in cylinder block will require cleaning with a 4.76 mm (3/16 inch) drill and tap handle to remove RTV.

CAUTION: If excessive RTV (wet or dry) accumulates in blind holes, the casting will crack when bolts are installed.





b. When all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol.

CAUTION: Do not use petroleum cleaners such as mineral spirits; they leave a film onto which RTV will not stick.

c. If cylinder block oil gallery plugs are removed, clean the threads and apply Loctite 290 or equivalent. Do not over-torque the plugs. Torque to 30 Nm (22 ft. lbs.).
2. Clean the cylinder block:

CAUTION: Use extreme care and do not damage or scratch the machined aluminum surfaces and the cylinder bores. Do not heat the cylinder block above 44° C (120° F). Using a soft scrub brush and solvent, clean the entire block of oil, debris, etc.





3. Inspect top of cylinder block for flatness using a precision straight edge and feeler gauge measure the surfaces contacting the cylinder head gasket for warpage.
^ Transverse Warpage standard is 0.024 mm (0.0009 inch) max. and service limit is 0.05 mm (0.0020 inch) max.
^ Longitudinal Warpage standard is 0.080 mm (0.0031 inch) max. and service limit is 0.10 mm (0.0040 inch) max. If warpage is greater than maximum, replace the cylinder block.





4. Inspect cylinders for scoring or vertical scratches:





5. Inspect cylinder bore diameter using a cylinder bore gauge, measure the cylinder bore diameter at positions A, B. and C in the transverse and longitudinal directions. Record these dimensions. Standard Diameter:
Cylinder Bore Diameter No. 1, 2, 3:
^ Standard: 81.99-82.01 mm (3.2280-3.2287 inch).
^ Service Limit: 82.035 mm (3.2297 inch) max.
^ (average X and Y direction measurements)
Cylinder Bore Diameter No. 4:
^ Standard: 82.00-82.02 mm (3.2283-3.2291 inch).
^ Service Limit: 82.045 mm (3.2301 inch) max.
^ (average X and Y direction measurements)
Cylinder Bore Out-of-Round and Taper:
^ Standard: 0.010 mm (0.0004 inch) max.
^ Service Limit: 0.050 mm (0.0020 inch) max.
^ If the diameter is greater than maximum, hone, or re-bore the worn or scored cylinders. If necessary, replace the cylinder block.





6. Using a sled gauge (dial indicator mounted on a steel block) or straight edge and feeler gauge, measure the cylinder liner height at positions A, B. C, and D at the top of the cylinder block. Liner height above or below cylinder block standard is Flush and service limit is 0.013 mm (0.0005 inch) max. If the liner height is below the cylinder block, the cylinder block may require surfacing or replacement. Top side of main bearing bore to cylinder head deck surface service limit is 189.26 mm (7.4511 inch) min.





7. Remove cylinder ridge reamer, if not previously completed during piston removal. If a ridge can be felt in the cylinder bore above the upper ring, use a ridge reamer to machine the piston ring ridge at the top of the cylinder.

CAUTION: Failure to remove a ridge can cause upper piston ring damage when new rings are installed.