Cylinder Block Assembly: Testing and 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)
0.50: 89.475 - 89.485 mm (3.5226 - 3.5230 inch)
4. 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 limit, replace the cylinder block.
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)
0.50: 89.500 - 89.515 mm (3.5236 - 3.5242 inch)
Reboring Limit: 0.5 mm (0.02 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.
Piston-to-Block Clearance:
Standard (New): 0.015 - 0.040 mm (0.0006 - 0.0016 inch)
Service Limit: 0.08 mm (0.003 inch)