Inspection of Cylinder Block

Remove the gasket material. Using a gasket scraper, remove all gasket material from the top surface of the cylinder block.

Clean the Cylinder Block. Using a soft brush and solvent, thoroughly clean the cylinder block.

Inspect the top surface of the cylinder block for flatness. Using a precision straightedge and feeler gauge, measure the cylinder block and manifold surfaces for distortion. Cylinder block gasket surface flatness Standard: Less than 0.05 mm (0.0019 in.) for overall. Less than 0.02 mm (0.0007 in.) for 100 mm (3.9370 in.) x 100 mm (3.9370 in.)

Inspect the cylinder bore diameter. Visually check the cylinder for vertical scratches. If deep scratches are found, replace the cylinder block.

Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at the points in the axial and transverse directions.

Standard diameter: 88.00 - 88.03 mm (3.4645 - 3.4657 in.)

Check the cylinder bore size code on the cylinder block.

Cylinder bore inside diameter

Size code	Cylinder Inner Diameter
A	88.00 - 88.01 mm (3.4645 - 3.4649 in.)
B	88.01 - 88.02 mm (3.4649 - 3.4653 in.)
C	88.02 - 88.03 mm (3.4653 - 3.4657 in.)

Check the piston size code on the piston top surface.

Piston outside diameter

Size code	Piston Outer Diameter
A	87.970 - 87.980 mm (3.46338 - 3.46377 in.)
B	87.980 - 87.990 mm (3.46377 - 3.46417 in.)
C	87.990 - 88.000 mm (3.46417 - 3.46456 in.)

Select a piston that matches the cylinder bore size class.

Clearance: 0.020 - 0.040 mm (0.00079 - 0.00157 in.)