Block and Piston Inspection
- Remove the pistons from the engine block (see CRANKSHAFT AND PISTON REMOVAL ).
- Check the piston for distortion or cracks.
- Measure the piston skirt diameter (A) at a point 10 mm (0.39 in) from the bottom of the skirt. There are two standard-size pistons (/ (slash) and B). The letter is stamped on the top of the piston. Letters are also stamped on the engine block as cylinder bore sizes.
Piston Diameter
Standard (New):
/ (slash): 85.980-85.990 mm (3.38503-3.38543 in)
B: 85.970-85.980 mm (3.38464-3.38503 in)
Service Limit:
/ (slash): 85.930 mm (3.38306 in)
B: 85.920 mm (3.38267 in)
Oversize Piston Diameter
0.25: 86.230-86.240 mm (3.39499-3.39527 in)
- Measure the wear and taper in direction X and Y at three levels in each cylinder as shown in illustration. If the measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the engine block has to be rebored, refer to step 7 after reboring.
Cylinder Bore Size
Standard (New):
A or I: 86.010-86.020 mm (3.38621-3.38661 in)
B or II: 86.000-86.010 mm (3.38582-3.38621 in)
Service Limit: 86.070 mm (3.38858 in)
Oversize
0.25: 86.250-86.260 mm (3.39567-3.39606 in)
Reboring Limit: 0.25 mm (0.010 in) max.
Bore Taper
Limit: (Difference between first and third measurement) 0.05 mm (0.002 in)
- Hone any scored or scratched cylinder bores (see CYLINDER BORE HONING ).
- Check the top of the engine block for warpage. Measure along the edges and across the center as shown in illustration.
Engine Block Warpage
Standard (New): 0.07 mm (0.002 in) max.
- 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 bore for excessive wear.
Piston-to-Cylinder Bore Clearance
Standard (New): 0.020-0.040 mm (0.00079-0.00157 in)
Service Limit: 0.05 mm (0.0020 in)