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

CYLINDER BLOCK

1. Inspect the cylinder block for chips, corrosion, scale deposits and rust. Also check for cracks and other damage.

Replace the cylinder block if significant damage is found.

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

Standard value: 0.03 mm or less Limit: 0.15 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 out-of-round (ovality) or taper of the cylinder exceeds the limit, or if the cylinder wall has scratches or scoring, bore the cylinder block to the appropriate oversize and hone it. After boring, install pistons and piston rings of the corresponding oversize.

Take measurements at the locations shown in the illustration.

Standard cylinder bore diameter: 76.50-76.53 mm Cylinder taper limit: 0.01 mm or less 4. If there is a ridge (ridge wear) at the top of the cylinder bore, remove it using the special tool.

5. Pistons are available in four oversizes.

Piston oversize and marking 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 oversize, calculate the bore diameter so that the standard piston-to-cylinder clearance is obtained. Make sure all pistons installed are of the same oversize.

Standard piston diameter is measured at 47 mm from the piston crown.

Piston-to-cylinder clearance (standard for new parts): 0.025 - 0.045 mm