Block and Piston Inspection
BLOCK AND PISTON INSPECTION1. Check the piston for distortion or cracks.
2. 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)
3. Measure wear and taper in directions X and Y at three levels in each cylinder as shown.
- If the measurements in any cylinder are beyond the oversize bore service limit, replace the cylinder block.
- If the block is to be rebored, refer to Piston Clearance Inspection (Go to step 5.) 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)
0.50: 89.500 - 89.515 mm (3.5236 - 3.5242 inch)
Bore Taper
Limit: (Difference between first and third measurement) 0.05 mm (0.002 inch)
Reboring Limit: 0.05 mm (0.002 inch)
4. 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)
5. Calculate the difference between the 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)
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)