Cylinder Block, Measurement

Cylinder Block, Measurement

Special tools: 9639, 9704





Turn block into upright position
Remove:
- oilway plugs at front and rear
- cooling jacket plug on right-hand side





Inspect cooling jacket visually
Check for:
- deposits in block
- leakage/corrosion of expansion plugs Remove expansion plugs as required.





Expansion plug removal
Drill 8 mm hole in plug.

Use drift and ring spanner to pry out plug.





Wipe bores clean
Inspect bores visually.





Measure cylinder bores
Use inside dial gauge 9639 (50100 mm), micrometer 9704 (50-100 mm) and a micrometer stand.

Set micrometer to bore diameter plus max. tolerance as marked on block.

Calibrate dial gauge using micrometer.





Measure wear
Check for maximum wear at right-angles to centerline of engine immediately below TDC.

Check for minimum wear in direction of centerline at BDC.





Classification
Each cylinder is identified by a classification marking (C, D, E or G) punched in the block.

Oversized bores may be designated OS1 or 0S2 as appropriate. This designation must be added after reboring.

Cylinder bore diameters
Standard
Bore marked C 96.00-96.01 mm (3.7795-3.7799 in)
Bore marked D 96.01-96.02 mm (3.7799-3.7803 in)
Bore marked E 96.02-96.03 mm (3.7803-3.7807 in)
Bore marked G 96.04-96.05 mm (3.7811-3.7815 in)

Oversize
Oversize 1 96.30 mm (3.7913 in)
Oversize 2 96.60 mm (3.8031 in)

Reboring should be carried out when wear reaches 0.10 mm (0.0039 in).





Remove cylinder block from stand
Clean block thoroughly and blow out all passages.