System Specifications
Cylinder blockWarping limit mm (in) 0.025 (0.00098)
(Mating surface with cylinder head)
Bore � Stroke mm (in) 99.5 � 79.0 (3.92 � 3.11)
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 boring limit (diameter) 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, piston 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 piston pin 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)
#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 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 degrees
(B), (D): Torque tightening
Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A - H) in alphabetical order.
Crank pulley
Temporarily tighten the crank pulley bolt
Tighten the crank pulley bolt to the specified angle
