Cylinder Block Measurement

SPECIAL TOOL
- Dial Gauge tool No. 999 9639, or equivalent
- Micrometer tool No. 999 9704, or equivalent

PROCEDURE





1. Measure cylinder bores
- Wipe bores clean and inspect visually.
- Measure bores using dial gauge 999 9639 (50-100 mm), micrometer 999 9704 and a micrometer stand.
- Set micrometer to bore diameter plus maximum tolerance as marked on block.
- Calibrate dial gauge using micrometer.





2. Measure wear
- Measure maximum wear at right angles to engine centerline immediately underneath TDC.
- Measure minimum wear in line with centerline at BDC.





3. Classification
- Each cylinder is identified by a classification marking (C,D,E or G) punched in the rear of the block.
- Oversize bores are indicated by abbreviations OS1 or OS2 as appropriate. This marking must be applied after reboring.

Cylinder bore diameters:

Standard
Bores marked C: 83.00-83.01 mm
Bores marked D: 83.01-83.02 mm
Bores marked E: 83.02-83.03 mm
Bores marked G: 83.04-83.05 mm

Oversize
Bores marked 0S1: 83.20-83.21 mm
Bores marked 0S2: 83.40-83.41 mm

Cylinders should be rebored when wear reaches 0.10 mm.