Service Limits & General Specifications

CRANKSHAFT END PLAY





^ Using a dial indicator, measure the clearance between the thrust bearings and the crankshaft arms when the crankshaft is moved from front to rear.
Standard 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit 0.30 mm (0.0118 inch)
^ If beyond the limit, replace the thrust bearings and measure again. If still beyond the limit, replace the crankshaft.

CONNECTING ROD SIDE CLEARANCE





^ Measure the side clearance between the connecting rod and crankshaft with a feeler gauge.
Standard 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit 0.40 mm (0.016 inch)
^ If beyond the limit, replace the connecting rod and measure again. If still beyond the limit, replace the crankshaft.

PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin Hole





^ Measure the inner diameter of piston pin hole "dp".
Standard diameter "dp"
Grade No. 0 21.993 - 21.999 mm (0.8659 - 0.8661 inch)
Grade No.1 21.999 - 22.005 mm (0.8661 - 0.8663 inch)

Outer Diameter of Piston Pin





^ Measure outer diameter of piston pin "Dp".
Standard diameter "Dp"
Grade No. 0 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No.1 21.995 - 22.001 mm (0.8659 - 0.8662 inch)

Piston and Piston Pin Interference Fit





Standard Interference Fit= "Dp - "dp"
Standard 0.002 mm - 0.006 mm (0.0001 - 0.0002 inch)
^ If clearance is exceeds specification, replace piston/piston pin assembly and connecting rod assembly with reference to specification of each part.
^ When replacing piston/piston pin assembly, refer to "PISTON-TO-CYLINDER BORE CLEARANCE".

PISTON RING SIDE CLEARANCE





^ Measure side clearance of piston ring and piston ring groove with feeler gauge.
Standard Side Clearance
Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 inch)
2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 inch)
Maximum Limit
Top ring 0.11 mm (0.0043 inch)
2nd ring 0.1 mm (0.004 inch)
Oil ring : -
^ If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings, replace piston

PISTON RING END GAP
^ Check if inner diameter of cylinder bore is within specification. Refer to "PISTON-TO-CYLINDER BORE CLEARANCE."





^ Insert piston ring until it is in the middle of the cylinder bore and measure the end gap.
Standard
Top ring 0.23 - 0.33 mm (0.0091 - 0.0130 inch)
2nd ring 0.33 - 0.48 mm (0.0130 - 0.0189 inch)
Oil ring 0.20 - 0.50 mm (0.0079 - 0.0197 inch)
Limit:
Top ring 0.54 mm (0.0213 inch)
2nd ring 0.80 mm (0.0315 inch)
Oil ring 0.95 mm (0.0374 inch)
^ If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

CONNECTING ROD BEND AND TORSION





Bend Limit 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) length
Torsion Limit 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length





^ If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)





^ Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod bolt to the specified torque, measure the connecting rod bearing housing big end inner diameter using an inside micrometer.
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 inch)

CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)





^ Measure inner diameter of piston pin bushing.
Standard
Grade No. 0 22.000 - 22.006 mm (0.8661 - 0.8664 inch)
Grade No.1 22.006 - 22.012 mm (0.8664 - 0.8666 inch)

Outer Diameter of Piston Pin





^ Measure outer diameter of piston pin.
Standard
Grade No. 0 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No. 1 21.995 - 22.001 mm (0.8659 - 0.8662 inch)

Connecting Rod Bushing Oil Clearance (Small End)





(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) - (Outer diameter of piston pin)
Standard 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
Limit 0.030 mm (0.0012 inch)
^ If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
^ If replacing the piston and piston pin assembly, refer to the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to "PISTON-TO-CYLINDER BORE CLEARANCE".
^ If replacing the connecting rod assembly, refer to "CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)".

Factory installed parts grading








^ Service parts apply only to grade 0.

CYLINDER BLOCK DISTORTION





^ Remove any old gasket material on the cylinder block surface, and remove any oil, scale, carbon, or other contamination using suitable tool.

CAUTION:
^ Be careful not to allow gasket flakes to enter the oil or coolant passages.

^ Measure the distortion on the block upper face at different points in six directions.
Distortion limit 0.10 mm (0.0039 inch)
^ If out of specification, resurface the cylinder block. The allowable amount of resurfacing is dependent on the amount of any cylinder head resurfacing. The resurfacing limit is [amount of cylinder head resurfacing] + [amount of cylinder head resurfacing] = 0.2 mm (0.008 inch).
Cylinder block height 214.95 - 215.05 mm (8.4626 - 8.4665 inch)

INNER DIAMETER OF MAIN BEARING HOUSING





^ Install the main bearing caps with the main bearings removed, and tighten the bolts to the specified torque.
^ Using a bore gauge, measure the inner diameter of the main bearing housing.
Standard 63.993 - 64.017 mm (2.5194 - 2.5203 inch)
^ If out of the standard, replace the cylinder block and main bearing caps as an assembly.

NOTE: These components cannot be replaced individually, since they were processed together.

PISTON-TO-CYLINDER BORE CLEARANCE





1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. The X axis is in the longitudinal direction of the engine.





Cylinder bore inner diameter





If it exceeds the limit, re bore all cylinders. Replace cylinder block if necessary.
Out-of-round (Difference between X - Y) less than 0.015 mm (0.0006 inch)
Taper (Difference between, C - A) less than 0.015 mm (0.0006 inch)





2. Check for scratches and seizure. If seizure is found, hone it.
^ If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.





3. Measure piston skirt diameter.
Piston diameter "A" : Refer to "PISTON. PISTON RING AND PISTON PIN.
Measuring point "a" (distance from the top) 41.0 mm (1.614 inch)





4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance at "B" 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
^ The piston-to-bore clearance is measured at the "B" level in the cylinder as shown.
5. Determine piston oversize according to amount of cylinder wear.
^ Oversize pistons are available for service.
^ If oversize piston is used, use it for all cylinders with oversize piston ring. Refer to "PISTON, PISTON RING AND PISTON PIN ".
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A".
Rebored size calculation : D = A + B - C
where,
D : Bored diameter
A : Piston diameter as measured
B : Piston-to-bore clearance
C : Honing allowance 0.02 mm (0.0008 inch)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted after boring.
8. Cut cylinder bores.
^ When any cylinder needs boring, all other cylinders must also be bored.
^ Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 inch) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
^ Measurement should be done after cylinder bore cools down.

OIL CLEARANCE OF CONNECTING ROD BEARING
Method by Calculation
1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to "ASSEMBLY".





3. Measure the inner diameter "C of each connecting rod (big end) as shown.





4. Measure the outer diameter "Dp" of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard 0.034 - 0.059 mm (0.0013 - 0.0023 inch)
Limit 0.070 mm (0.0028 inch)
6. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings. Refer to "HOW TO SELECT CONNECTING ROD BEARINGS".

Method of Using Plastigage





^ Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
^ Cut a Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod bolts to the specified torque. Refer to "CYLINDER BLOCK".

CAUTION: Never rotate the crankshaft.

^ Remove the connecting rod cap and bearings, and using the scale on the Plastigage bag, measure the Plastigage width.

NOTE: The procedure when the measured value exceeds the repair limit is same as that described in "Method by Calculation ".

OIL CLEARANCE OF MAIN BEARING
Method by Calculation
1. Install the main bearings to the cylinder block and bearing cap. Refer to "ASSEMBLY".





2. Calculate the main bearing clearance. (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal)
Standard 0.035 - 0.045 mm (0.0014 - 0.0018 inch)
Limit 0.065 mm (0.0026 inch)
3. If the calculated clearance exceeds the specified limit, replace the bearings. Refer to "HOW TO SELECT MAIN BEARINGS ".

Method of Using Plastigage





Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
^ Cut a Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Install the main bearings and main bearing caps. Refer to "ASSEMBLY".

CAUTION: Never rotate the crankshaft.

^ Remove the main bearing caps and bearings, and using the scale on the Plastigage bag, measure the Plastigage width.

NOTE: The procedure when the measured value exceeds the repair limit is same as that described in "Method by Calculation"".

CRUSH HEIGHT OF MAIN BEARING





^ When the bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of the bearing must protrude. Refer to "ASSEMBLY for tightening procedure.
Standard : There must be a crush height.
^ If the standard is not met, replace main bearings.

CRUSH HEIGHT OF CONNECTING ROD BEARING





^ When the connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of the bearing must protrude. Refer to "ASSEMBLY for tightening procedure.
Standard : There must be a crush height.
^ If the standard is not met, replace connecting rod bearings.

OUTER DIAMETER OF MAIN BEARING CAP BOLTS





Check specifications for the re-use of the main bearing cap bolts.
^ Measure d1 and d2 as shown.
^ For d2, select the minimum diameter in the measuring area.
^ If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.
Limit (d1 - d2) 0.11 mm (0.0043 inch)

OUTER DIAMETER OF CONNECTING ROD BOLTS





^ Measure outer diameter d as shown.
Standard 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit 7.75 mm (0.3051 inch)
^ When the value of d exceeds the limit (when it becomes thinner) replace the bolt with a new one.








CYLINDER BLOCK