System Specifications
Cylinder blockWarping limit
Mating surface with cylinder head mm (in) 0.025 (0.00098)
Grinding limit mm (in) 0.1 (0.004)
Standard height mm (in) 201.0 (7.91)
Taper mm (in) Standard 0.015 (0.0006)
Out-of-roundness mm (in) Standard 0.010 (0.0004)
Cylinder to piston clearance at 20�C (68�F) mm (in)
Standard -0.010 - 0.010 (-0.00039 - 0.00039)
Cylinder inner diameter boring limit mm (in) To 100.005 (3.9372)
Piston
Piston grade point mm (in) 38.2 (1.504)
Outer diameter mm (in)
Standard
A 99.505 - 99.515 (3.9175 - 3.9179)
B 99.495 - 99.505 (3.9171 - 3.9175)
0.25 (0.0098) OS 99.745 - 99.765 (3.9270 - 3.9277)
0.50 (0.0197) OS 99.995 - 100.015 (3.9368 - 3.9376)
Piston ring
Piston ring gap mm (in)
Top ring Standard 0.20 - 0.35 (0.0079 - 0.0138)
Second ring Standard 0.37 - 0.52 (0.0146 - 0.0205)
Oil ring Standard 0.20 - 0.50 (0.0079 - 0.0197)
Clearance ring groove mm (in)
Top ring Standard 0.040 - 0.080 (0.0016 - 0.0031)
Second ring Standard 0.030 - 0.070 (0.0012 - 0.0028)
Connecting rod and connecting rod bearing
Bend or twist per 100 mm (3.94 in) in length mm (in)
Service limit 0.10 (0.0039)
Thrust clearance mm (in) Standard 0.070 - 0.330 (0.0028 - 0.0130)
Oil clearance mm (in) Standard 0.016 - 0.044 (0.0006 - 0.0017)
Bearing size (Thickness at center) mm (in)
Standard 1.492 - 1.501 (0.0587 - 0.0591)
0.03 (0.0012) US 1.510 - 1.513 (0.0594 - 0.0596)
0.05 (0.0020) US 1.520 - 1.523 (0.0598 - 0.0600)
0.25 (0.0098) US 1.620 - 1.623 (0.0638 - 0.0639)
Clearance between piston pin and bushing mm (in)
Standard 0 - 0.022 (0 - 0.0009)
CRANKSHAFT AND CRANKSHAFT BEARING
Bending limit mm (in) 0.035 (0.0014)
Crank pin
Out-of-roundness mm (in) 0.003 (0.0001)
Cylindricality mm (in) 0.004 (0.0002)
Grinding limit (dia.) mm (in) To 51.750 (2.0374)
Crank journal
Out-of-roundness mm (in) 0.005 (0.0002)
Cylindricality mm (in) 0.006 (0.0002)
Grinding limit (dia.) mm (in) To 59.758 (2.3527)
Crank pin outer diameter mm (in)
Standard 51.984 - 52.000 (2.0466 - 2.0472)
0.03 (0.0012) US 51.954 - 51.970 (2.0454 - 2.0461)
0.05 (0.0020) US 51.934 - 51.950 (2.0446 - 2.0453)
0.25 (0.0098) US 51.734 - 51.750 (2.0368 - 2.0374)
Crank journal outer diameter mm (in)
Standard 59.992 - 60.008 (2.3619 - 2.3625)
0.03 (0.0012) US 59.962 - 59.978 (2.3607 - 2.3613)
0.05 (0.0020) US 59.942 - 59.958 (2.3599 - 2.3605)
0.25 (0.0098) US 59.742 - 59.758 (2.3520 - 2.3527)
Bearing size (Thickness at center) mm (in)
#1, #3
Standard 1.998 - 2.011 (0.0787 - 0.0792)
0.03 (0.0012) US 2.017 - 2.020 (0.0794 - 0.0795)
0.05 (0.0020) US 2.027 - 2.030 (0.0798 - 0.0799)
0.25 (0.0098) US 2.127 - 2.130 (0.0837 - 0.0839)
#2, #4, #5
Standard 2.000 - 2.013 (0.0787 - 0.0793)
0.03 (0.0012) US 2.019 - 2.022 (0.0795 - 0.0796)
0.05 (0.0020) US 2.029 - 2.032 (0.0799 - 0.0800)
0.25 (0.0098) US 2.129 - 2.132 (0.0838 - 0.0839)
Thrust clearance mm (in) Standard 0.030 - 0.115 (0.0012 - 0.0045)
Oil clearance mm (in) Standard 0.010 - 0.030 (0.0004 - 0.0012)
Cylinder block connecting bolts
Tighten the 10 mm on the LH side (A - D)
Tighten the 10 mm bolts on RH side (E - J)
Tighten the LH side bolts (A - D)
Tighten the RH side bolts (E - J)
Tighten the LH side bolts (A - D)
(A), (C): Angle tightening
Tightening angle 90°
(B), (D): Torque tightening
Tighten the RH side bolts (E - J)
Tighten the 8 mm and 6 mm bolts on the LH side (A - H)
Crank pulley
Tightening torque 47 Nm (4.8 kgf-m, 34.7 ft-lb)
Tightening angle 60 ± 5°