INSPECTION


Piston rings

Checking piston ring gap

Push piston ring squarely from above down to approx. 15 mm from bottom end of cylinder. And then, check piston ring gap using feeler gauges.
Piston ring Dimensions in mm
 Standard value
 Limit
No.1 compression ring
 0.20 - 0.40
 1.0
No.2 compression ring
 0.20 - 0.40
 1.0
Oil scraper ring
 0.25 - 0.50
 1.0

Checking ring-to-groove clearance

Clean ring groove before checking. And then, check piston ring-to-groove clearance using feeler gauges.
Piston ring Dimensions in mm
 Standard value
 Limit
No.1 compression ring
 0.06 - 0.09
 0.25
No.2 compression ring
 0.05 - 0.08
 0.25
Oil scraper ring
 0.03 - 0.06
 0.15

Piston

Piston and cylinder dimensions
Check piston and cylinder dimensions.
Dimensions in mm
 Piston
 Cylinder bore
Basic dimension
 80.96
 81.01

Checking piston projection at TDC

Piston projection at TDC must be measured when new pistons or a short engine is installed. Install the appropriate cylinder head gasket depending upon piston projection, according to following table:
note
  • Turn engine clockwise to measure piston projection at TDC.
  • If different values are determined during the projection measurement, use the largest dimension for selecting the gasket.
Piston projection mm
 Identification hole / notches
0.91 - 1.00
 1
1.01 - 1.10
 2
1.11 - 1.20
 3

Cylinder head gasket identification


    1: Part No.
    2: Production control code
    3: Holes
Installation position: Identification faces upwards.

BEARING SHELL

AXIAL CLEARANCE
Check axial clearance of bearing shell.
Limit: 0.37 mm

RADIAL CLEARANCE
Check radial clearance with Plastigage.
Limit: 0.08 mm
note Do not rotate crankshaft when checking radial clearance.

CYLINDER BLOCK

Checking cylinder bores

Using Internal dial gauge (50 to 100 mm), take measurements at 3 positions in both transverse "A" and longitudinal "B" directions, as illustrated. Difference between actual and nominal diameter: not more than 0.10 mm.