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 (0.0020 in.),
Less than 0.02 mm (0.0008 in.) / 150 x 150
Inspect cylinder bore diameter.
Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block.
Inspect cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter :
92.00 ~ 92.03 mm (3.6220 ~ 3.6232 in.)
Check the cylinder bore size code on the cylinder block.
Class | Size code | Cylinder bore inner diameter |
A | A | 92.00 ~ 92.01 mm (3.6220 ~ 3.6224 in.) |
B | B | 92.01 ~ 92.02 mm (3.6224 ~ 3.6228 in.) |
C | C | 92.02 ~ 92.03 mm (3.6228 ~ 3.6232 in.) |
Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark | Size |
0.1 | 0.1 mm (0.004 in) |
0.25 | 0.25 mm (0.010 in) |
The size of piston is stamped on top of the piston.
Measure the outside diameter of the piston to be used.
According to the measured O.D(Outer Diameter), calculate the new bore size.
New bore size = piston O.D + 0.03 to 0.05 mm (0.0012 to 0.0020 in) (clearance between piston and cylinder) - 0.01 mm (0.0004 in) (honing margin.)
Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
Check the clearance between the piston and cylinder.
Standard : 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in)
When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.
