Cylinder Block

CYLINDER BLOCK

DISASSEMBLY

1. Remove the cylinder head, timing belt, oil pump case, flywheel, pistons and crankshaft.

2. Remove the oil pressure switch.

INSPECTION

1. Check the cylinder block for chips, corrosion, scale deposits and rust. Also check for cracks and other damage. Replace the cylinder block if significant defects are found.

2. Using a straightedge and feeler gauge, check the cylinder block gasket surface for distortion. Make sure the surface is clean and free of old gasket material and foreign particles.

Standard value: 0.03 mm or less Limit: 0.1 mm or less

3. Measure the cylinder bore diameter with a cylinder gauge at three levels along the height in directions "A" and "B". If the cylinder out-of-round (ovality) or taper exceeds the limit, or if the cylinder wall has scratches or scoring, bore the cylinder to the appropriate oversize and hone the cylinders. After boring the cylinder block, install pistons and piston rings of the corresponding oversize. Take measurements at the locations shown in the illustration.

Standard cylinder bore diameter: 82 mm Cylinder taper limit: 0.01 mm or less

5. Pistons are available in four oversizes.

Piston oversize and mark: mm 0.25 mm: 0.25 0.50 mm: 0.50 0.75 mm: 0.75 1.00 mm: 1.00 6. When boring and honing cylinders to an oversize, calculate the bore diameter so that the standard piston-to-cylinder clearance is obtained after machining. Make sure all pistons being installed are of the same oversize.

7. Standard piston diameter measurements are taken at 47 mm from the piston crown.

Piston-to-cylinder clearance (specified limit for new parts): 0.02 - 0.04 mm 8. For a used piston-cylinder pair, the maximum allowable clearance is 0.085 mm or less.