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.





Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 94.990 - 95.003 mm (3.7400 - 3.7403 inch)
Maximum diameter: 95.06 mm (3.7425 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.





6. Inspect main bearing cap bolts.
Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter: 10.76 - 10.97 mm (0.4236 - 0.4319 inch)
Minimum outside diameter: 10.40 mm (0.4094 inch)
If the diameter is less than minimum, replace the bolt.