Remove the gasket material.
Using a gasket scraper, remove all the 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 straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05 mm (0.002 in),
Less than 0.02 mm (0.0008 in) / 100 x 100 (3.937 x 3.937in)
Inspect the cylinder bore.
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
71.00 ~ 71.03 mm (2.7952 ~ 2.7964 in)
Check the cylinder bore size code on the cylinder block.
Class | Mark | Inside Diameter |
a | A | 71.00 ~ 71.01 mm (2.79528 ~ 2.79567 in.) |
b | B | 71.01 ~ 71.02 mm (2.79567 ~ 2.79606 in.) |
c | C | 71.02 ~ 71.03 mm (2.79606 ~ 2.79646 in.) |
Check the piston size code on the piston top face.
Class | Mark | Inside Diameter |
a | A | 70.965 ~ 70.975 mm (2.79390 ~ 2.79429 in.) |
b | B | 70.975 ~ 70.985 mm (2.79429 ~ 2.79469 in.) |
c | C | 70.985 ~ 70.995 mm (2.79469 ~ 2.79508 in.) |
Select the piston corresponding to cylinder bore class.
Clearance : 0.025 ~ 0.045 mm (0.00098 ~ 0.00177 in.)
