INSPECTION OF CYLINDER BLOCK 1. REMOVE GASKET MATERIAL Using a gasket scraper, remove all gasket material from the cylinder block surfaces. 2. CLEAN CYLINDER BLOCK Using a soft brush and solvent, clean the block. 3. INSPECT CYLINDERS Visually inspect cylinders for vertical scratches. If deep scratches are present, rebore all six cylinders. (See page EM-50) 4. INSPECT CYLINDER BLOCK WARPAGE Warpage: Limit 0.05 mm (0.0020 in.) If warpage is greater than the specified value, replace the cylinder block. 5. MEASURE CYLINDER BORE Using a cylinder micrometer, measure the cylinder bore at positions A, B and C in the thrust and axial directions. If any of the following measurements are not within the specification, rebore the cylinder. (See page EM-50) (a) Cylinder diameter is greater than the maximum permissible limit. On standard sized piston Maximum diameter: 83.25 mm (3.2776 in.) On oversized piston (O/S 0.50) Maximum diameter: 83.75 mm (3.2972 in.) On oversized piston (O/S 0.75) Maximum diameter: 84.00 mm (3.3071 in.) On oversized piston (O/S 1.00) Maximum diameter: 84.25 mm (3.3169 in.) (b) If the difference between measurements A, B and C is greater than the taper limit, rebore the cylinder. (See page EM-50) Taper limit: 0.02 mm (0.0008 in.) (c) If the difference between thrust and axial measurements is greater than the out-of-round limit, rebore the cylinder. (See page EM-50) Out-of-round limit: 0.02 mm (0.0008 in.) 6. REMOVE CYLINDER RIDGE If wear is less than 0.2 mm (0.008 in.), use a ridge reamer to machine the piston ring ridge at the top of the cylinder. Front ① Thrust Direction ② Axial Direction A 10 mm (0.39 in.) Middle B C 10 mm (0.39 in.) EM0602 EM1788 EM0498