Cylinder Block
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Illustration 1 | g01412583 |
(1) Cylinder block |
- Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. Maximum allowable clearance is
0.05 mm (0.002 inch) - Repair limit is
0.20 mm (0.008 inch) - Resurface the top of the block if the repair limit is reached.
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Illustration 2 g01412585 (2) Cylinder liner - Measure the inside diameter of the cylinder sleeve that is parallel to the crankshaft. Measure the inside diameter of the cylinder liner that is in a perpendicular position to the crankshaft. Measure the top, the middle, and the bottom of the cylinder liner. Refer to Table 1 for tolerances of the cylinder liner.
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Tolerances of Cylinder Sleeves | |||
Standard at Assembly | Repair Limit(1) | Service Limit(2) | |
Inside Diameter | |
|
|
Out of Round | |
N/A | N/A |
Taper | |
N/A | N/A |
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(1) | The repair limit is the maximum dimension or the repair limit is the minimum dimension that is specified for a part. Repair a part if the repair limit is reached. |
(2) | The service limit is the maximum dimension or the service limit is the minimum dimension that is specified for a part. Replace the part if the service limit is reached. |
- Bore the cylinder to the specified oversize dimension if the inside diameter reaches the repair limit but the inside diameter does not reach the service limit. Refer to Table 2.
- Hone the liner to
+0.25 mm (+0.010 inch) or+0.50 mm (+0.020 inch) oversize. Hone the liner to an accuracy within0.010 to 0.045 mm (0.0004 to 0.0018 inch) . - Determine the oversize dimension that is necessary in order to clean up the cylinder if any liner has uneven wear.
- Replace all cylinder liners that are in excess of the service limit.
Note: Refinish all liners to the same oversize dimension. Use a ridge reamer to cut the ridge of the cylinder if the liner is in good condition. Hone the cylinder bore.
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Oversize Bore | Cylinder Bore Size |
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Illustration 3 | g01412586 |
(3) Service limit of cylinder liner is |
Note: Replace all cylinder liners that exceed the service limit.
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Illustration 4 | g00529962 |
Cylinder liner |
Use the following procedure to repair the cylinder liners:
- Set up a boring machine on the cylinder block. Align the boring machine with the center of the bottom of the cylinder liner with the less worn area.
- Bore the liner until the thickness is
0.50 mm (0.020 inch) . - Remove the remainder of the liner. Be careful not to damage the cylinder block.
- Install a new liner. Align the liner with the top of the cylinder block.
- The bore of the cylinder must be
102.000 to 102.035 mm (4.0157 to 4.0171 inch) . - Diameter for the main bearing bores
95.000 mm (3.7401 inch) - Maximum diameter of the main bearing bores
95.022 mm (3.7410 inch) - New height of deck from centerline of crankshaft to deck
307.00 ± 0.05 mm (12.087 ± 0.002 inch)
- The bore of the cylinder must be
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