System Specifications
Cylinder blockSurface warpage limit (mating with cylinder head) 0.025 mm (0.00098 in)
Grinding limit 0.1 mm (0.004 in)
Standard height 201.0 mm (7.91 in)
Cylinder inner diameter Standard
A 99.505 - 99.515 mm (3.9175 - 3.9179 in)
B 99.495 - 99.505 mm (3.9171 - 3.9175 in)
Taper Standard 0.015 mm (0.0006 in)
Out-of-roundness Standard 0.010 mm (0.0004 in)
Piston clearance Standard -0.010 - 0.010 mm (-0.00039 - 0.00039 in)
Cylinder inner diameter boring limit To 100.005 mm (3.9372 in)
Piston
Outer diameter Standard
A 99.505 - 99.515 mm (3.9175 - 3.9179 in)
B 99.495 - 99.505 mm (3.9171 - 3.9175 in)
0.25 mm (0.0098 in) OS 99.745 - 99.765 mm (3.9270 - 3.9278 in)
0.50 mm (0.0197 in) OS 99.995 - 100.015 mm (3.9368 - 3.9376 in)
Piston pin
Clearance between piston and piston pin 0.004 - 0.008 mm (0.0002 - 0.0003 in)
Degree of fit Piston pin can be fitted into position with thumb at 20°C (68°F)
Piston ring
Ring closed gap
Top ring Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Second ring Standard 0.37 - 0.52 mm (0.0144 - 0.0203 in)
Oil ring Standard 0.20 - 0.50 mm (0.0079 - 0.0197 in)
Ring groove gap
Top ring Standard 0.040 - 0.080 mm (0.0016 - 0.0031 in)
Second ring Standard 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Connecting rod
Bend or twist per 100 mm (3.94 in) in length
Limit 0.10 mm (0.0039 in)
Thrust clearance Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in)
Oil clearance Standard 0.016 - 0.044 mm (0.00063 - 0.0017 in)
Bearing of large end
Bearing size (Thickness at center)
Standard 1.492 - 1.501 mm (0.0587 - 0.0591 in)
0.03 mm (0.0012 in) US 1.510 - 1.513 mm (0.0594 - 0.0596 in)
0.05 mm (0.0020 in) US 1.520 - 1.523 mm (0.0598 - 0.0600 in)
0.25 mm (0.0098 in) US 1.620 - 1.623 mm (0.0638 - 0.0639 in)
Bushing of small end
Clearance between piston pin and bushing 0 - 0.022 mm (0 - 0.0009 in)
Crankshaft
Bend limit 0.035 mm (0.0014 in)
Crank pin
Out-of -roundness 0.003 mm (0.0001 in)
Cylindricality 0.004 mm (0.0002 in)
Grinding limit (dia.) To 51.750 mm (2.0374 in)
Crank journal
Out-of -roundness 0.005 mm (0.0002 in)
Cylindricality 0.006 mm (0.0002 in)
Grinding limit (dia.) To 59.758 mm (2.3527 in)
Crank pin outer diameter
Standard 51.984 - 52.000 mm (2.0466 - 2.0472 in)
0.03 mm (0.0012 in) US 51.954 - 51.970 mm (2.0454 - 2.0461 in)
0.05 mm (0.0020 in) US 51.934 - 51.950 mm (2.0446 - 2.0453 in)
0.25 mm (0.0098 in) US 51.734 - 51.750 mm (2.0368 - 2.0374 in)
Crank journal outer diameter
Standard 59.992 - 60.008 mm (2.3619 - 2.3625 in)
0.03 mm (0.0012 in) US 59.962 - 59.978 mm (2.3607 - 2.3613 in)
0.05 mm (0.0020 in) US 59.942 - 59.958 mm (2.3599 - 2.3605 in)
0.25 mm (0.0098 in) US 59.742 - 59.758 mm (2.3520 - 2.3527 in)
Thrust clearance 0.030 - 0.115 mm (0.0012 - 0.0045 in)
Oil clearance 0.010 - 0.030 mm (0.0001 - 0.0012 in)
Main bearing
#1, #3
Standard 1.998 - 2.011 mm (0.0787 - 0.0792 in)
0.03 mm (0.0012 in) US 2.017 - 2.020 mm (0.0794 - 0.0795 in)
0.05 mm (0.0020 in) US 2.027 - 2.030 mm (0.0798 - 0.0799 in)
0.25 mm (0.0098 in) US 2.127 - 2.130 mm (0.0837 - 0.0839 in)
#2, #4, #5
Standard 2.000 - 2.013 mm (0.0787 - 0.0793 in)
0.03 mm (0.0012 in) US 2.019 - 2.022 mm (0.0795 - 0.0796 in)
0.05 mm (0.0020 in) US 2.029 - 2.032 mm (0.0799 - 0.0800 in)
0.25 mm (0.0098 in) US 2.129 - 2.132 mm (0.0838 - 0.0839 in)
Cylinder block connecting bolts
LH side (A - D) 10 N-m (1.0 kgf-m, 7.4 ft-lb)
RH side (E - J) 10 N-m (1.0 kgf-m, 7.4 ft-lb)
LH side (A - D) 18 N-m (1.8 kgf-m, 13.3 ft-lb)
RH side (E - J) 18 N-m (1.8 kgf-m, 13.3 ft-lb)
LH side (A - D) further
(A), (C): Angle tightening 90°
(B), (D): Torque tightening 40 N-m (4.1 kgf-m, 29.5 ft-lb)
RH side (E - J) further 90°
8 mm and 6 mm LH side (A - H)
(A) - (G) 25 N-m (2.5 kgf-m, 18.4 ft-lb)
(H) 6.4 N-m (0. 7 kgf-m, 4.7 ft-lb)
Crank Pulley
Temporarily tighten 44 N-m (4.5 kgf-m, 32.5 ft-lb)
Tightening torque 130 N-m (13.3 kgf-m, 95.9 ft-lb)
If the tightening angle of crank pulley bolt is less than 45°, the bolt is damaged. In this case, the bolt must be replaced.
Temporarily tighten 44 N-m (4.5 kgf-m, 32.5 ft-lb)
Tighten bolt 45°to 60°