Block & Piston Inspection
- Remove the piston from the cylinder block (see Crankshaft & Piston Removal ).
- Check the piston for distortion or cracks.
- Measure the piston diameter at a point 16.0 mm (0.63 in.) from the bottom of the skirt.
Piston Diameter
Standard (New): 88.975-88.985 mm (3.5029-3.5033 in.)
Service Limit: 88.965 mm (3.5026 in.)
Oversize Piston Diameter
0.25: 89.225-89.235 mm (3.5128-3.5132 in.)
0.50: 89.475-89.485 mm (3.5226-3.5230 in.)
- Measure wear and taper in directions X and Y at three levels in each cylinder as shown.
- If the bore size or taper in any cylinder is over the service limit, the block must be rebored.
- If the measurements in any cylinder are beyond the oversize bore service bore service limit, replace the cylinder block.
Cylinder Bore Size
Standard (New): 89.000-89.015 mm (3.5039-3.5045 in.)
Service Limit: 89.065 mm (3.5065 in)
Oversize
0.25: 89.250-89.265 mm (3.5138-3.5144 in.)
0.50: 89.500-89.515 mm (3.5236-3.5242 in.)
Reboring Limit: 0.5 mm (0.02 in.)
Bore Taper
Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.)
- Scored or scratched cylinder bores must be honed.
- Check the top of the cylinder block for warpage. Measure along the edges and across the center as shown.
Cylinder Block Warpage
Standard (New): 0.07 mm (0.003 in.) max.
Service Limit: 0.10 mm (0.004 in.)
- Calculate the difference between cylinder bore diameter and piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive wear.
Piston-to-Block Clearance
Standard (New): 0.015-0.040 mm (0.0006-0.0016 in.)
Service Limit: 0.08 mm (0.003 in.)