Cylinder Block

Front bracket of SOHC engine block

Removal

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 switch.

Inspection

Cylinder Block

PROCEDURE

1. Remove all traces of gaskets, sealant, dirt, oil, lubricant and other foreign materials from the cylinder block. Visually inspect the cylinder block for rust, corrosion, cracks or any other damage.

2. Clean the mating surfaces of the cylinder head and cylinder block to remove all traces of gasket. Using a metal straightedge and feeler gauge, check the flatness of the cylinder block mating surface in six directions.
Flatness deviation: 0.05 mm
Maximum flatness deviation: 0.1 mm
3. Measure the cylinder bore diameters in diametrically opposite directions, at three positions along the cylinder height. If the cylinder bore diameters exceed the specified values, or the bores are out-of-round, tapered, scored or worn, bore the cylinder block and install new pistons and piston rings of the repair size.
Standard cylinder bore diameter: 75.5 mm
Cylinder taper: 0.02 mm maximum
4. If there is a step 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 nearest oversize, maintain the piston-to-cylinder clearance and make sure the pistons are 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