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 11 mm (0.4 inch) from the bottom of the skirt.
Piston Diameter:
Standard (New): 71.977 - 71.995 mm (2.8337 - 2.8344 inch)
Service Limit: 71.97 mm (2.833 inch)
Oversize Piston Diameter: 0.25: 72.227 - 72.245 mm (2.8436 - 2.8443 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): 72.000 - 72.020 mm (2.8346 - 2.8354 inch)
Service Limit: 72.07 mm (2.837 inch)
Oversize: 0.25: 72.250 - 72.270 mm (2.8445 - 2.8453 inch)
Reboring limit: 0.25 mm (0.010 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): 0.005 - 0.043 mm (0.0002 - 0.0017 inch)
Service Limit: 0.05 mm (0.002 inch)