Cylinder Block
Cylinder Block
. Unit: mm (inch)
Surface flatness
Standard Less than 0.03 (0.0012)
Limit 0.10 (0.0039)
Cylinder bore
Inner diameter
Standard
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)
Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)
Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610)
Wear limit 0.20 (0.0079)
Out-of-round (X - Y) Less than 0.015 (0.0006)
Taper (A - B - C) Less than 0.015 (0.0006)
Main journal inner diameter grade (Without bearing)
Grade No.A 63.993 - 63.994 (2.5194 - 2.5194)
Grade No.B 63.994 - 63.995 (2.5194 - 2.5195)
Grade No.C 63.995 - 63.996 (2.5195 - 2.5195)
Grade No.D 63.996 - 63.997 (2.5195 - 2.5196)
Grade No.E 63.997 - 63.998 (2.5196 - 2.5196)
Grade No.F 63.998 - 63.999 (2.5196 - 2.5196)
Grade No.G 63.999 - 64.000 (2.5196 - 2.5197)
Grade No.H 64.000 - 64.001 (2.5197 - 2.5197)
Grade No.J 64.001 - 64.002 (2.5197 - 2.5198)
Grade No.K 64.002 - 64.003 (2.5198 - 2.5198)
Grade No.L 64.003 - 64.004 (2.5198 - 2.5198)
Grade No.M 64.004 - 64.005 (2.5198 - 2.5199)
Grade No.N 64.005 - 64.006 (2.5199 - 2.5199)
Grade No.P 64.006 - 64.007 (2.5199 - 2.5200)
Grade No.R 64.007 - 64.008 (2.5200 - 2.5200)
Grade No.S 64.008 - 64.009 (2.5200 - 2.5200)
Grade No.T 64.009 - 64.010 (2.5200 - 2.5201)
Grade No.U 64.010 - 64.011 (2.5201 - 2.5201)
Grade No.V 64.011 - 64.012 (2.5201 - 2.5202)
Grade No.W 64.012 - 64.013 (2.5202 - 2.5202)
Grade No.X 64.013 - 64.014 (2.5202 - 2.5202)
Grade No.Y 64.014 - 64.015 (2.5202 - 2.5203)
Grade No.4 64.015 - 64.016 (2.5203 - 2.5203)
Grade No.7 64.016 - 64.017 (2.5203 - 2.5203)
Difference in inner diameter between cylinders
Standard Less than 0.03 (0.0012)
Piston, Piston Ring and Piston Pin
AVAILABLE PISTON
. Unit: mm (In)
Piston skirt diameter "A"
Standard
Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594)
Grade No. 2 95.490 - 95.500 (3.7594 - 3 7598)
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602)
0.20 (0.0079) oversize (Service) 95.680 - 95.710 (3.7669 - 3.7681)
"a" dimension 41.0 (1.614)
Piston pin hole diameter
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661)
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663)
Piston clearance to cylinder block 0.010 - 0.030 (0.0004 - 0.0012)
PISTON RING
. Unit: mm (inch)
Side clearance
Top
Standard 0.045 - 0.080 (0.0018 - 0.0031)
Limit 0.11 (0.0043)
2nd
Standard 0.030 - 0.070 (0.0012 - 0.0028)
Limit 0.1 (0.004)
Oil ring 0.065 - 0.135 (0.0026 - 0.0053)
End gap
Top
Standard 0.23 - 0.33 (0.0091 - 0.0130)
Limit 0.54 (0.0213)
2nd
Standard 0.33 - 0.48 (0.0130 - 0.0189)
Limit 0.80 (0.0315)
Oil (rail ring)
Standard 0.20 - 0.50 (0.0079 - 0.0197)
Limit 0.95 (0.0374)
PISTON PIN
. Unit: mm (inch)
Piston pin outer diameter
Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659)
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662)
Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing clearance
Standard 0.005 - 0.017 (0.0002 - 0.0007)
Limit 0.030 (0.0012)
* Values measured at ambient temperature of 20 degrees C (68 degrees F)
Connecting Rod
. Unit: mm (inch)
Center distance 144.15 - 144.25 (5.6752 - 5.6791)
Bend [per 100 (3.94)]
Limit 0.15 (0.0059)
Torsion [per 100 (3.94)]
Limit 0.30 (0.0118)
Connecting rod small end inner diameter 23.980 - 24.000 (0.9441 - 0.9449)
Piston pin bushing inner diameter*
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664)
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666)
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Side clearance
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Limit 0.40 (0.0157)
* After installing in connecting rod
Crankshaft
. Unit: mm (inch)
Main journal dia. "Dm" grade
Grade No.A 59.975-59.974(2.3612-2.3612)
Grade No.B 59.974-59.973(2.3612-2.3611)
Grade No.C 59.973-59.972(2.3611-2.3611)
Grade No.D 59.972-59.971(2.3611-2.3611)
Grade No.E 59.971-59.970(2.3611-2.3610)
Grade No.F 59.970-59.969(2.3610-2.3610)
Grade No.G 59.969-59.968(2.3610-2.3609)
Grade No.H 59.968-59.967(2.3609-2.3609)
Grade No.J 59.967-59.966(2.3609-2.3609)
Grade No.K 59.966-59.965(2.3609-2.3608)
Grade No.L 59.965-59.964(2.3608-2.3608)
Grade No.M 59.964-59.963(2.3608-2.3607)
Grade No.N 59.963-59.962(2.3607-2.3607)
Grade No.P 59.962-59.961(2.3607-2.3607)
Grade No.R 59.961-59.960(2.3607-2.3606)
Grade No.S 59.960-59.959(2.3606-2.3606)
Grade No.T 59.959-59.958(2.3606-2.3605)
Grade No.U 59.958-59.957(2.3605-2.3605)
Grade No.V 59.957-59.956(2.3605-2.3605)
Grade No.W 59.956-59.955(2.3605-2.3604)
Grade No.X 59.955-59.954(2.3604-2.3604)
Grade No.Y 59.954-59.953(2.3604-2.3603)
Grade No.4 59.953-59.952(2.3603-2.3603)
Grade No.7 59.952-59.951(2.3603-2.3603)
Pin journal dia. "Dp"
Grade No.0 51.968-51.974(2.0460-2.0462)
Grade No.1 51.962-51.968(2.0457-2.0460)
Grade No.2 51.956-51.962(2.0445-2.0457)
Center distance "r" 40.36-40.44(1.5890-1.5921)
Out-of-round (X - Y)
Standard Less than 0.002(0.0001)
Taper (A - B)
Standard Less than 0.002(0.0001)
Runout [TIR*]
Limit Less than 0.10 (0.0039)
Free end play
Standard 0.10-0.25(0.0039-0.0098)
Limit 0.30(0.0118)
* Total Indicator reading
Available Main Bearing
Available Main Bearing:
UNDERSIZE Unit: mm (inch)
. 0.25 (0.0098)
Thickness 2.132 - 2.140 (0.0839 - 0.0843)
Main journal diameter "Dm"
. Grind so that bearing clearance is the specified value.
Available Connecting Rod Bearing
CONNECTING ROD BEARING
Grade number 0
Thickness "T" mm (inch) 1.500 - 1.503 (0.0591 - 0.0592)
Identification color (mark) Black
Grade number 1
Thickness "T" mm (inch) 1.503 - 1.506 (0.0592 - 0.0593)
Identification color (mark) Brown
Grade number 2
Thickness "T" mm (inch) 1.506 - 1.509 (0.0593 - 0.0594)
Identification color (mark) Green
UNDERSIZE Unit: mm (In)
. 0.25 (0.0098)
Thickness 1.626 - 1.634 (0.0640 - 0.0643)
Crank pin journal diameter "Dp"
. Grind so that bearing clearance is the specified value.
. Unit: mm (inch)
Drive plate runout [TIR]* Less than 0.15 (0.0059)
* Total indicator reading
BEARING CLEARANCE.Unit: mm (inch)
Main bearing clearance
Standard 0.035 - 0.045 (0.0014 - 0.0018)
Limit 0.065 (0.0026)
Connecting rod bearing clearance
Standard 0.034 - 0.059 (0.0013 - 0.0023)
Limit 0.070 (0.0028)