Cylinder Block Assembly: Service and Repair
Cylinder Block InspectionReference: Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check gasketed surface for distortion. If flatness exceeds its limit, correct or replace it.
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Oversize piston diameter: 88.470 - 88.490 mm (3.4831 - 3.4838 inch)
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B - C
D: Cylinder bore diameter to be rebored
A: Piston diameter as measured
B: Piston clearance = 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
C: Allowance for honing = 0.02 mm (0.0008 inch)
5) Rebore and hone cylinder to calculated dimension.
NOTE: Before reboring, install lower crankcase in place and tighten to specification to avoid distortion of bearing bores.
6) Measure piston clearance after honing.