Cylinder Block Assembly: 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 (diameter) To 100.005 mm (3.9372 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)
Bearing of large end
Oil clearance Standard 0.016 0.044 mm (0.00063 0.0017 in)
Bearing size (Thickness at center)
Standard 1.492 1.501 mm (0.0587 0.0591 in)
0.03 (0.0012) US 1.510-1.513 mm (0.0594-0.0596 in)
0.05 (0.0020) US 1.520-1.523 mm (0.0598-0.0600 in)
0.25 (0.0098) US 1.620-1.623 mm (0.0638-0.0639 in)
Bushing of small end
Clearance between piston pin and bushing Standard 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 (0.0012) US 51.954 - 51.970 mm (2.0454 - 2.0461 in)
0.05 (0.0020) US 51.934 - 51.950 mm (2.0446 - 2.0453 in)
0.25 (0.0098) 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 (0.0012) US 59.962 - 59.978 mm (2.3607 - 2.3613 in)
0.05 (0.0020) US 59.942 - 59.958 mm (2.3599 - 2.3605 in)
0.25 (0.0098) US 59.742 - 59.758 mm (2.3520 - 2.3527 in)
Thrust clearance Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in)
Oil clearance Standard 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 (0.0012) US 2.017 - 2.020 mm (0.0794 - 0.0795 in)
0.05 (0.0020) US 2.027 - 2.030 mm (0.0798 - 0.0799 in)
0.25 (0.0098) 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 (0.0012) US 2.019 - 2.022 mm (0.0795 - 0.0796 in)
0.05 (0.0020) US 2.029 - 2.032 mm (0.0799 - 0.0800 in)
0.25 (0.0098) US 2.129 - 2.132 mm (0.0838 - 0.0839 in)
Cylinder block connecting bolts:
Tighten the 10 mm cylinder block connecting bolts on the LH side (A - D) in alphabetical order.
Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order.
Tighten the LH side cylinder block connecting bolts (A D) further in alphabetical order.
Tighten the RH side cylinder block connecting bolts (E J) further in alphabetical order.
Tighten the LH side cylinder block connecting bolts (A D) further in alphabetical order.
(A), (C): Angle tightening
Tightening angle: 90°
(B), (D): Torque tightening
Tighten the RH side cylinder block connecting bolts (E - J) in alphabetical order.
Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence.
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 (0.0098) OS 99.745 - 99.765 mm (3.9270 - 3.9278 in)
0.50 (0.0197) OS 99.995 100.015 mm (3.9368 - 3.9376 in)
Piston Pin
Clearance between piston and piston pin:
Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in)
Degree of fit Piston pin must 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)
Crankshaft pully bolt:
Temporarily 44 N-m (4.5 kgf-m, 32.5 ft-lb)
Tighten torque 180 Nm (18.4 kgf-m, 132.8 ft. lb.)
Tightening angle of the crank pulley bolt is 65° or more