Block and Piston Inspection
Inspection1. Remove the crankshaft and pistons
2. Check the piston for distortion or cracks.
3. Measure the piston diameter at a point 13 mm (0.5 inch) from the bottom of the skirt.
Piston Diameter
Standard (New): 74.98 - 74.99 mm (2.9520 - 2.9524 inch)
Service Limit: 74.97 mm (2.9516 inch)
Oversize Piston Diameter
0.25: 75.23 - 75.24 mm (2.9618 - 2.9622 inch)
0.50: 75.48 - 75.49 mm (2.9716 - 2.9720 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 is to be rebored, refer to step 6 after reboring.
Cylinder Bore Size
Standard (New): 75.00 - 75.02 mm (2.9528 - 2.9535 inch)
Service Limit: 75.07 mm (2.9555 inch)
Oversize:
0.25: 75.25 - 75.27 mm (2.9626 - 2.9634 inch)
0.50: 75.50 - 75.52 mm (2.9724 - 2.9732 inch)
Reboring limit: 0.5 mm (0.02 inch) max.
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 block for warpage. Measure along the edges and across the center as shown.
Engine Block Warpage
Standard (New): 0.07 mm (0.003 inch) max.
Service Limit: 0.10 mm (0.004 inch)
7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive wear.
Piston-to-Cylinder Clearance
Standard (New): 0.010 - 0.040 mm (0.0004 - 0.0016 inch)
Service Limit: 0.05 mm (0.002 inch)