Cylinder Block

Front bracket of SOHC engine block

Disassembly

PROCEDURE

1. Remove the cylinder head, timing belt, front cover, flywheel, pistons and crankshaft.

2. Using the special tool (09260-32000), remove the oil pressure sensor.

Inspection

PROCEDURE
1. Remove all gasket residue, sealant, dirt, oil, grease and other foreign material from the engine block. Visually check the engine block for rust, corrosion, cracks or any other damage.

2. Clean the mating surfaces of the cylinder head and engine block to remove gasket residue. Using a steel straight edge and feeler gauge, check the flatness of the block mating surface at six points.
Flatness: 0.05 mm
Maximum flatness: 0.1 mm

3. Measure the cylinder bore diameters in two directions at right angles, at three levels along the cylinder height. If the bore diameters exceed the specified limits, the cylinder bore is out of round or tapered, or the cylinder surface is damaged or worn, bore the cylinder block and install new oversize pistons and piston rings.
Standard cylinder bore diameter: 75.5 mm

Cylinder taper: 0.02 mm maximum

4. If there is a ridge at the top of the cylinder, remove it using a special tool.
5. Oversize pistons are available in four sizes: 0.25, 0.5, 0.75 and 1.00 mm.
6. When boring cylinders to the next oversize, maintain the piston-to-cylinder clearance and make sure the pistons are of the same oversize.

Measure the outer diameter of each piston at a right angle (90°) to the piston pin, at 12 mm from the bottom of the piston skirt.

Piston-to-cylinder clearance: 0.025-0.045 mm