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.





Calculate the average of thrust diameter and axial diameter at the "A" position in the illustration.
Calculate the average of thrust diameter and axial diameter at the "B" position in the illustration.
Standard diameter 82.000 to 82.013 mm (3.2284 to 3.2289 inch)
If the value obtained at step (b) or (c) is not within the range of the standard diameter, replace the cylinder block.





Piston Diameter
Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 12 mm (0.472 inch) from the piston head.
Piston diameter 81.975 to 81.993 mm (3.2274 to 3.2281 inch)

Piston Oil Clearance
Subtract each piston diameter measurement from each cylinder bore diameter measurement.
Standard oil clearance 0.007 to 0.038 mm (0.0003 to 0.0015 inch)
Maximum oil clearance 0.10 mm (0.0039 inch)

Ring Groove Clearance
Ring groove clearance 0.03 to 0.07 mm (0.0012 to 0.0028 inch)





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





Connecting rod small end bore diameter 20.011 to 20.023 mm (0.7878 to 0.7883 inch)





Piston pin bore diameter 20.013 to 20.025 mm (0.7879 to 0.7884 inch)





Piston pin outer diameter 20.004 to 20.016 mm (0.7876 to 0.7880 inch)

Subtract each piston pin diameter measurement from the bushing inside diameter measurement.





Standard oil clearance

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 0.052 mm (0.0011 to 0.0020 inch)
Maximum oil clearance 0.080 mm (0.0031 inch)

Connecting Rod Sub-Assembly
Maximum misalignment 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
Maximum twist 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)

Connecting Rod Bolt
Standard diameter 8.7 to 8.8 mm (0.3425 to 0.3465 inch)
Minimum diameter mm (inch)

Crankshaft Thrust Clearance
Standard thrust clearance 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance 0.24 mm (0.0094 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 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 out-of-round 0.02 mm (0.0008 inch)
Diameter 44.992 to 45.000 mm (1.7713 to 1.7717 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)

Crankshaft pulley
Torque 120 Nm (1,224 kgf-cm, 89 ft. lbs.)