Sidekick JS 2D Soft Top 2WD L4-1.6L (1997)
Piston: Testing and Inspection
INSPECTION
Pistons
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Inspect piston for faults, cracks or other damaged. Damaged or faulty piston should be replaced.
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Piston diameter: As indicated in figure, piston diameter should be measured at a position 15 mm (0.59 inch) from piston skirt end in the direction
perpendicular to piston pin.
Piston Diameter:
Standard: 74.970 - 94.990 mm (2.9516-2.9523 inch)
Oversize 0.25 mm (0.0098 inch): 75.220 - 75.230 mm (2.9614 - 2.9618 inch)
0.50 mm (0.0196 inch): 75.470-75.480 mm (2.9712 - 2.9716 inch)
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Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be
within specification as given below. If it is out of specification, rebore cylinder and use oversize piston.
Piston Clearance: 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
NOTE: Cylinder bore diameters used here are measured in thrust direction at two positions.
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Ring groove clearance: Before checking, piston grooves must be clean, dry and free of carbon. Fit new piston ring into piston groove, and measure
clearance between ring and ring land by using thickness gauge. If clearance is out of specification, replace piston.
Ring Groove Clearance:
Top: 0.03 - 0.07 mm (0.0012 - 0.0027 inch)
2nd: 0.02 - 0.06 mm (0.0008 - 0.0023 inch)
Piston Pin