87546-ZV1-F20 Honda MARK, EMERGENCY START (E)

Basic Block
Cylinder Liner Projection
1P5510 Liner Projection Tool Group 1P2403 Dial Indicator1P5512 Contact Point .88 in. (22.4 mm) long1P2402 Gauge Body1P5507 Gauge1P2394 Adapter Plate8B7548 Push-Puller (crossbar only)3H465 Plates (2)S1589 Bolt 5/8-11 NC-1.75 in. (44.5 mm) long1S379 Washer (copper)1D4595 Bolt 5/8-11NC-6.00 in. (152.4 mm) long2S736 WasherThe correct cylinder liner projection is important to prevent a leak between the liner, cylinder head, and block. Check cylinder liner projection above the spacer plate as follows:1. Be sure that the surfaces of the cylinder block, cylinder liner, and the spacer plate are clean.2. Install the spacer plate gasket and spacer plate (4) on the cylinder block. Use S1589 Bolts (1) with two 1S379 Washers on each bolt to hold the spacer plate to the cylinder block. Put two bolts with washers on each side of the opening for the cylinder liner. Tighten the bolts evenly, in four steps; 10 lb. ft. (14 N m), 25 lb. ft. (35 N m), 50 lb. ft. (70 N m), and 70 lb. ft. (95 N m). To keep from moving bolts and washers as each liner is checked install two bolts with washers on each side of each cylinder liner, along the complete length of the spacer plate.3. Install the cylinder liner without seals in the cylinder block. Put adapter plate (7) on the cylinder liner as shown. Install crossbar (2) with 1D4595 Bolts (3), and 2S736 Washers, and 3H465 Plates (5) as shown. Tighten the bolts evenly, in four steps; 5 lb. ft. (7 N m), 15 lb. ft. (20 N m), 25 lb. ft. (35 N m), and 50 lb. ft. (70 N m). The measurement from the bottom of crossbar (2) to the spacer plate, must be the same on both sides of the cylinder liner.4. Install the 1P5512 Contact Point on dial indicator (6). Put the dial indicator in the 1P2402 Gauge Body. To adjust the dial indicator to zero, put dial indicator and gauge body on the 1P5507 Gauge. Move the dial indicator until the hand moves 1/4 turn. Tighten bolt on body to hold the dial indicator in this position. Turn the dial face until the zero is in alignment with the hand.
MEASURING CYLINDER LINER PROJECTION
1. S1589 Bolt with two 1S379 Washers. 2. Crossbar. 3. 1D4595 Bolt. 4. Spacer plate. 5. 3H465 Plates. 6. 1P2403 Dial Indicator. 7. 1P2394 Adapter plate.5. Measure the cylinder liner projection as close as possible to the four corners of the adapter plate on the liner. The liner projection must be .0013 to .0069 in. (0.033 to 0.175 mm). The difference between the four measurements must not be more than .002 in. (0.05 mm). The difference in the average cylinder liner projection of liners next to each other must not be more than .002 in. (0.05 mm). If the liner projection changes from point to point around the liner, turn the liner to a new position in the bore. If the liner projection is still not to specifications, move the liner to a different bore.6. When the cylinder liner projection is correct, put a temporary mark on the liner and the spacer plate so at final installation the liner can be installed in the correct position.Cylinder liner projection can be adjusted by the removal of material from (machining) the contact face of the cylinder block with the use of 8S3140 Cylinder Block Counterboring Tool Arrangement. The instructions for the use of the tool group are in Special Instruction Form No. FM055228.