System Specifications

CYLINDER BLOCK

Machining Specifications
Surface 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.)
Limit 0.050 mm (0.0020 in.)

Out-of-roundness
Standard 0.010 mm (0.0004 in.)
Limit 0.050 mm (0.0020 in.)

Piston clearance
Standard 0.010 - 0.010 mm (-0.00039 - 0.00039 in.)
Limit 0.030 mm (0.0012 in.)
Cylinder boring limit (diameter) 100.005 mm (3.937 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 standard diameter 23.000 - 23.006 mm (0.9055 - 0.9057 in.)

Piston Ring
Ring closed gap mm (in)
Top ring
Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in.)
Limit 1.0 mm (0.039 in.)

Second ring
Standard 0.37 - 0.52 mm (0.0144 - 0.0203 in.)
Limit 1.0 mm (0.039 in.)

Oil ring
Standard 0.20 - 0.50 mm (0.0079 - 0.0197 in.)
Limit 1.5 mm (0.059 in.)
Ring groove gap

Top ring
Standard 0.040 - 0.080 mm (0.0016 - 0.0031 in.)
Limit 0.15 mm (0.0059 in.)

Second ring
Standard 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
Limit 0.15 mm (0.0059 in.)

Connecting Rod
Bend twist per 100 mm (3.94 in) in length
Limit 0.10 mm (0.0039 in.)

Side clearance of large end
Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in.)
Limit 0.4 mm (0.016 in.)
Bearing of large end

Oil clearance
Standard 0.016 - 0.044 mm (0.00063 - 0.0017 in.)
Limit 0.05 mm (0.0020 in.)

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
Standard 0 - 0.022 mm (0 - 0.0009 in.)
Limit 0.030 mm (0.0012 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 59.750 mm (2.3524 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.)
0.25mm (0.0098 in.) US 59.742 - 59.758 mm (2.3520 - 2.3527 in.)

Side clearance
Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in.)
Limit 0.25 mm (0.0098 in.)

Oil clearance mm (in)
Standard 0.010 - 0.030 mm (0.0004 - 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.)

Crank Pulley
Tighten 180 Nm (18.4 kgf-m, 132.8 ft-lb)