Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the contacting surface of the cylinder block and the manifolds for warpage..
Flatness of cylinder block gasket surface
Standard : Less than 0.05 mm (0.0019 in.) for all
Less than 0.02 mm (0.0007 in.) for 100 mm (3.9370 in.) x 100 mm (3.9370 in.)
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 :
88.00 ~ 88.03 mm (3.4645 ~ 3.4657 in.)
Measure position points (from the bottom of the cylinder block)
: 110.7 mm(4.3582 in.) / 160 mm (6.2992 in.) / 210 mm (8.2677 in.)
Check the cylinder bore size code on the cylinder block.
Size Code | Cylinder Bore 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 face.
Stamp the grade mark of basic diameter with rubber stamp.
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 the piston related to cylinder bore class.
Clearance : 0.020 ~ 0.040 mm (0.00079 ~ 0.00157 in.)
