Inspecting Engine Components; Inspecting Cylinders; Inspecting Piston - TOHATSU TLDI 40 Service Manual

Inspecting Engine Components

Inspecting Cylinders

• Cylinder bore (using cylinder gauge)
Standard value
68.05 mm
(2.679 in)
• Measure the area showing the greatest wear.
• Also replace when difference between minimum
and maximum cylinder bore is 0.06 mm
(0.002 in) or more.

Inspecting Piston

• Outer diameter of piston skirt (using micrometer)
Standard value
67.96 mm
(2.676 in)
Measure at point 12 mm (0.47 in) from the bottom
of the piston skirt.
• Piston clearance (between cylinder and piston)
Standard value
0.08 to 0.12 mm
(0.003 to 0.005 in) (0.008 in) or more
• Inner diameter of piston pin hole (using cylinder
gauge)
Standard value
17.00 mm (0.67 in) Depends on clearance with pin
• Clearance between piston pin and pin hole
Standard value
Tight: 0.003 mm
(0.00012 in)
Loose: 0.007 mm
(0.00028 in)
Service limit
Replace when 68.11 mm
(2.682 in) or more
Service limit
Replace when 67.90 mm
(2.673 in) or more
Service limit
Replace when 0.21 mm
Service limit
Service limit
Replace when 0.02 mm
(0.0008 in) or more
4-42
CYLINDER HEAD SIDE