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Fitting Pistons

  1. Measure cylinder bores and pistons to be fitted. Measure piston with micrometer at bottom of skirt at right angles to piston pin. If clearance exceeds specifications, replace piston.
  2. If cylinder bore is worn or tapered beyond specifications, cylinder must be bored and oversize pistons installed. Oversize pistons are available in 0.020", 0.040" and 0.060" (0.50, 1.00 and 1.50 mm).
    CYLINDER BORE SPECIFICATIONS

    Application Wear Limits In. (mm)
    Standard Bore 3.701-3.703 (94.00-94.05)
    Bore Wear Limit .008 (.20)
    Taper .0008 (.020)
    Difference Between Cyls .002 (.05)
    Fig 1: Measuring Ring End Gap
    G09336477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Use 0.001 - 0.002" (0.03 - 0.05 mm) feeler gauge with pull scale to check clearance of oversize pistons. Force of 2.2-5.5 lbs. (1.0-2.5 kg) must not be exceeded when pulling feeler gauge from cylinder.
  4. Measure piston ring gaps in cylinder. If cylinder has not been bored, check gap with ring in lowest part of cylinder. Check clearance of piston ring in ring groove. Always install rings with marks facing upward.
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