Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Block and Piston Inspection
- Remove the crankshaft and the pistons (see CRANKSHAFT AND PISTON REMOVAL ).
- Check the piston for distortion or cracks.
- Measure the piston skirt diameter (A) at a point 16 mm (0.6 in) from the bottom of the skirt.
Piston Diameter
Standard (New): 72.969-72.979 mm (2.8728-2.8732 in)
Service Limit: 72.967 mm (2.8727 in)
Oversize Piston Diameter
0.25: 73.219-73.229 mm (2.8826-2.8830 in)
- Measure wear and taper in direction Y at three levels in 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 to be rebored, refer to step 7 after reboring.
Cylinder Bore Size
Standard (New): 73.000-73.015 mm (2.8740-2.8746 in)
Service Limit: 73.065 mm (2.8766 in)
Oversize
0.25: 73.250-73.265 mm (2.8839-2.8844 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.
- 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 (0.003 in) max.
Service Limit: 0.10 mm (0.004 in)
- 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 engine block for excessive wear.
Piston-to-Cylinder Clearance
Standard (New): 0.021-0.046 mm (0.0008-0.0018 in)
Service Limit: 0.05 mm (0.002 in)
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.