Piston
PISTON TO PISTON PIN OIL CLEARANCEPiston Pin Hole Diameter
Measure the inner diameter of piston pin hole with inside micrometer.
Standard: 21.993 - 22.005 mm (0.8659 - 0.8663 inch)
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with micrometer.
Standard: 21.989 - 22.001 mm (0.8657 - 0.8662 inch)
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 inch)
^ If the calculated value is out of the standard, replace piston and piston pin assembly.
^ When replacing piston and piston pin assembly, refer to "HOW TO SELECT PISTON".
NOTE:
^ Piston is available together with piston pin as assembly.
^ Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only "0" grade is available.)
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
^ Using bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. ("X" and "Y" directions at "A", "B" and "C") ("Y" is in longitudinal direction of engine)
Standard inner diameter: 95.500 - 95.530 mm (3.7598 - 3.7610 inch)
Wear limit: 0.2 mm (0.008 inch)
Out-of-round (Difference between "X" and "Y"): 0.015 mm (0.0006 inch)
Taper limit (Difference between "A" and "C"): 0.01 mm (0.0004 inch)
^ If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the inner wall.
^ Oversize piston is provided. When using oversize piston, rebore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard.
CAUTION: When using oversize piston, use over size pistons for all cylinders with oversize piston rings.
Oversize (OS): 0.2 mm (0.008 inch)
Piston Skirt Diameter
Measure the outer diameter of piston skirt with micrometer.
Measure point: Distance from the top 41.0 mm (1.614 inch)
Standard: 95.480 - 95.510 mm (3.7590 - 3.7602 inch)
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction "Y", position "B").
(Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).
Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
Limit: 0.08 mm (0.0031 inch)
^ If calculated value exceeds the limit, replace piston and piston pin assembly. Refer to "HOW TO SELECT PISTON".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bored size calculation: D = A + B - C where,
D: Bored diameter
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 inch)
2. Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores.
NOTE:
^ When any cylinder needs boring, all other cylinders must also be bored.
^ Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 inch) or so in diameter at a time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE: Measurement should be done after cylinder bore cools down.
PISTON, PISTON RING AND PISTON PIN
Available Piston
Piston Ring
Piston Pin