Block and Piston Inspection
Inspection1. Remove the piston from the cylinder block.
2. Check the piston for distortion or cracks.
3. Measure the piston diameter at a point 16.0 mm (0.63 inch) from the bottom of the skirt.
Piston Diameter
Standard (New): 88.975 - 88.985 mm (3.5029 - 3.5033 inch)
Service Limit: 88.965 mm (3.5026 inch)
Oversize Piston Diameter
0.25: 89.225 - 89.235 mm (3.5128 - 3.5132 inch)
4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the block. If the block has to be rebored, refer to step 7 after reboring.
Cylinder Bore Size
Standard (New): 89.000 - 89.015 mm (3.5039 - 3.5045 inch)
Service Limit: 89.065 mm (3.5065 inch)
Oversize
0.25: 89.250 - 89.265 mm (3.5138 - 3.5144 inch)
Reboring Limit: 0.25 mm (0.01 inch)
Bore Taper
Limit: (Difference between first and third measurement) 0.05 mm (0.002 inch)
5. Scored or scratched cylinder bores must be honed.
6. 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 inch) max.
Service Limit: 0.10 mm (0.004 inch)
7. 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 inch)
Service Limit: 0.08 mm (0.003 inch)