Cylinder Block Assembly: Specifications
Cylinder Block Warpage
Maximum warpage 0.05 mm (0.0020 inch)
Cylinder Bore
Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter 79.000 to 79.013 mm (3.1102 to 3.1107 inch)
Maximum diameter 79.133 mm (3.1155 inch)
If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
Piston Diameter
Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a piston of 28.0 mm (1.102 inch) from the top the piston head.
Piston diameter 78.917 to 78.927 mm (3.1070 to 3.1074 inch)
Piston Oil Clearance
Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.073 to 0.096 mm (0.0029 to 0.0038 inch) for 2WD
0.065 to 0.088 mm (0.0026 to 0.0035 inch) for 4WD
Maximum oil clearance:
0.10 mm (0.0039 inch) for 2WD
0.09 mm (0.0035 inch) for 4WD
Ring groove clearance
Piston Ring End Gap
Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.
Standard end gap
Maximum end gap
Piston Pin Oil Clearance
Piston pin bore diameter 20.006 to 20.015 mm (0.7876 to 0.7880 inch)
Piston pin outer diameter 20.004 to 20.013 mm (0.7876 to 0.7879 inch)
Connecting rod small end bore diameter 20.012 to 20.021 mm (0.7879 to 0.7882 inch)
Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance 0.002 to 0.011 mm (0.0001 to 0.0004 inch)
Maximum oil clearance 0.011 mm (0.0004 inch)
Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance -0.001 to 0.017 mm (-0.00004 to 0.0007 inch)
Maximum oil clearance 0.017 mm (0.0007 inch)
Piston Diameter
Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a piston of 28.0 mm (1.102 inch) from the top the piston head.
Piston diameter 78.917 to 78.927 mm (3.1070 to 3.1074 inch)
Piston Oil Clearance
Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.073 to 0.096 mm (0.0029 to 0.0038 inch) for 2WD
0.065 to 0.088 mm (0.0026 to 0.0035 inch) for 4WD
Maximum oil clearance:
0.10 mm (0.0039 inch) for 2WD
0.09 mm (0.0035 inch) for 4WD
Ring groove clearance
Piston Ring End Gap
Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.
Standard end gap
Maximum end gap
Piston Pin Oil Clearance
Piston pin bore diameter 20.006 to 20.015 mm (0.7876 to 0.7880 inch)
Piston pin outer diameter 20.004 to 20.013 mm (0.7876 to 0.7879 inch)
Connecting rod small end bore diameter 20.012 to 20.021 mm (0.7879 to 0.7882 inch)
Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance 0.002 to 0.011 mm (0.0001 to 0.0004 inch)
Maximum oil clearance 0.011 mm (0.0004 inch)
Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance -0.001 to 0.017 mm (-0.00004 to 0.0007 inch)
Maximum oil clearance 0.017 mm (0.0007 inch)
Crankshaft Thrust Clearance
Standard thrust clearance 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, measure the thrust washer thickness.
If the thickness is not as specified, replace the thrust washer.
HINT: Thrust washer thickness is 2.430 to 2.480 mm (0.0957 to 0.0976 inch).
Crankshaft
Maximum circle runout 0.03 mm (0.0012 inch)
Diameter 47.988 to 48.000 mm (1.8893 to 1.8898 inch)
Maximum taper and distortion 0.02 mm (0.0008 inch)
Diameter 43.992 to 44.000 mm (1.7320 to 1.7323 inch)
Maximum taper and distortion 0.02 mm (0.0008 inch)
Crankshaft Bearing Cap Set Bolt
Standard diameter 7.3 to 7.5 mm (0.287 to 0.295 inch)
Minimum diameter 7.3 mm (0.287 inch)
Connecting Rod Thrust Clearance
Standard thrust clearance 0.160 to 0.342 mm (0.0063 to 0.0135 inch)
Maximum thrust clearance 0.342 mm (0.0135 inch)
Connecting Rod Oil Clearance
Standard oil clearance 0.028 to 0.060 mm (0.0011 to 0.0024 inch)
Maximum oil clearance 0.080 mm (0.0032 inch)
Crankshaft Pulley
Torque 138 Nm (1,407 kgf-cm, 102 ft. lbs.)