Check the pistons for distortion or cracks. Measure the piston skirt diameter at a point 11 mm (0.43 in) from the bottom of the skirt. There are two standard-size pistons ( A and B). The letter is stamped on the top of the piston. Letters are also stamped on the engine block as the cylinder bore sizes.
Piston Skirt Diameter
Standard (New):
A:
85.980?85.990 mm (3.38503?3.38543 in)
B:
85.970?85.980 mm (3.38464?3.38503 in)
Service Limit:
A:
85.930 mm (3.38306 in)
B:
85.920 mm (3.38267 in)
2.
Measure the wear and taper in direction X and Y at three levels inside each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the engine block is being rebored, check the piston-to-cylinder bore clearance.
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 Bore
0.25:
86.250?86.260 mm (3.39566?3.39606 in)
Reboring limit:
0.25 mm (0.0098 in) max.
Bore Taper
Limit:
(Difference between first and third measurement) 0.05 mm (0.0020 in)
3.
Hone any cored or scratched cylinder bores if needed.
4.
Check the top of the engine block for warpage. Measure along the edges and across the center as shown.
Engine Block Warpage
Standard (New):
0.07 mm (0.002 in) max.
5.
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 the 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)
4.
All Removed Parts - Install
1.
Install the parts in the reverse order of removal.
