Measuring Cylinder Bore Diameter; Deck Flatness Inspection; Measuring Cylinder Bore Out-Of-Round - Suzuki XL7 2007 Service Manual

1D-166 Engine Mechanical:

Measuring Cylinder Bore Diameter

Measure the cylinder bore diameter 37 mm (1.457 in)
from the deck face using the J 8087.
Compare your results with the "Engine Mechanical
Specifications". If the cylinder diameter exceeds the
specifications, the cylinder block may be oversized to
0.25 mm (0.010 in). There is only one size of oversized
pistons and rings available for service.
Measuring Cylinder Bore Taper
1. Measure the cylinder bore along the thrust surfaces,
perpendicular to the crankshaft centerline, at 10 mm
(0.397 in) below the deck surface and record your
measurement.
2. Measure the cylinder bore along the thrust surfaces,
perpendicular to the crankshaft centerline, at 100
mm (3.976 in) below the deck surface and record
your measurement.
3. Calculate the difference between the 2
measurements. The result will be the cylinder taper.
4. Compare your results with the "Engine Mechanical
Specifications". If the cylinders exceed the
specifications, the cylinder block may be oversized
to 0.25 mm (0.010 in). There is only one size of
oversized pistons and rings available for service.

Measuring Cylinder Bore Out-of-Round

1. Measure both the thrust and non-thrust cylinder
diameter at 10 mm (0.397 in) below the deck.
Record your measurements.
2. Calculate the difference between the 2
measurements. The result will indicate out-of-round
at the upper end of the cylinder.
3. Measure both the thrust and non-thrust cylinder
diameter at 100 mm (3.976 in) below the deck
surface. Record your measurements.
4. Calculate the difference between the 2
measurements. The result will indicate out-of-round
at the lower end of the cylinder.
5. Compare your results with the "Engine Mechanical
Specifications". If the cylinders exceed these
specifications, the cylinder block may be oversized
to 0.25 mm (0.010 in). There is only one size of
oversized pistons and rings available for service.

Deck Flatness Inspection

1. Ensure the engine block decks are clean and free of
gasket material.
2. Inspect the surface for any imperfections or
scratches that could inhibit proper cylinder head
gasket sealing.
3. Place a straight-edge diagonally across the cylinder
block deck face surface.
4. Measure the clearance between the straight-edge
and the cylinder block deck face using a feeler gage
at 4 points along the straight-edge.
5. If the warpage is less than 0.05 mm (0.002 in), the
cylinder block deck surface does not require
resurfacing.
6. If the warpage is between 0.05-0.20 mm (0.002-
0.008 in) or any imperfections or scratches that
could inhibit proper cylinder head gasket sealing are
present, the cylinder block deck surface requires
resurfacing.
7. If resurfacing is required the maximum amount that
can be removed is 0.25 mm (0.010 in).
8. If the cylinder block deck surface requires more than
0.25 mm (0.010 in) material removal the block must
be replaced.
Reference: "Engine Block Assemble: ".