Service Limits & General Specifications
PISTON AND PISTON PIN CLEARANCEInner Diameter of Piston Pin Hole
^ Measure the inner diameter of piston pin hole dp.
Standard diameter dp
Grade No. 0: 21.993 - 21.999 mm (0.8659 - 0.8661 inch)
Grade No. 1: 21.999 - 22.005 mm (0.8661 - 0.8663 inch)
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin Dp.
Standard diameter Dp
Grade No. 0: 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No. 1: 21.995 - 22.001 mm (0.8659 - 0.8662 inch)
Piston and Piston Pin Interference Fit
Standard Interference Fit = Dp - dp
Standard: 0.002 mm (0.0001 inch) - 0.006 mm (0.0002 inch) = -0.0004 mm (-0.0001 inch)
^ If clearance is exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each part.
PISTON RING SIDE CLEARANCE
^ Measure side clearance of piston ring and piston ring groove with feeler gauge.
Standard Side Clearance
Top ring: 0.045 - 0.080 mm (0.0018 - 0.0031 inch)
2nd ring: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Oil ring: 0.065 - 0.135 mm (0.0026 - 0.0053 inch)
Maximum Limit
Top ring: 0.11 mm (0.0043 inch)
2nd ring: 0.1 mm (0.004 inch)
Oil ring: -
^ If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings, replace piston
PISTON RING END GAP
^ Insert piston ring until it is in the middle of the cylinder bore and measure the end gap.
Standard
Top ring: 0.23 - 0.33 mm (0.0091 - 0.0130 inch)
2nd ring: 0.33 - 0.48 mm (0.0130 - 0.0189 inch)
Oil ring: 0.20 - 0.50 mm (0.0079 - 0.0197 inch)
Limit:
Top ring: 0.54 mm (0.0213 inch)
2nd ring: 0.80 mm (0.0315 inch)
Oil ring: 0.95 mm (0.0374 inch)
^ If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.
CONNECTING ROD BEND AND TORSION
Bend: Limit 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) length
Torsion: Limit 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length
^ If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)
^ Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod nut to the specified torque, measure the connecting rod bearing housing big end inner diameter using an inside micrometer.
Standard: 55.000 - 55.013 mm (2.1654 - 2.1659 inch)
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
^ Measure inner diameter of piston pin bushing.
Standard
Grade No. 0: 22.000 - 22.006 mm (0.8661 - 0.8664 inch)
Grade No. 1: 22.006 - 22.012 mm (0.8664 - 0.8666 inch)
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin.
Standard
Grade No. 0: 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No. 1: 21.995 - 22.001 mm (0.8659 - 0.8662 inch)
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) (Outer diameter of piston pin)
Standard: 0.005 - 0.017 mm (0.0002 - 0.007 inch)
Limit: 0.030 - mm (0.0012 inch)
^ If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
^ If replacing the piston and piston pin assembly, refer to the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used.
Factory installed parts grading:
^ Service parts apply only to grade 0.
CYLINDER BLOCK DISTORTION
^ Using a scraper, remove any old gasket material on the cylinder block surface, and remove any oil, scale, carbon, or other contamination.
CAUTION: Be careful not to allow gasket flakes to enter the oil or coolant passages.
^ Measure the distortion on the block upper face at different points in six directions.
Distortion limit: 0.10 mm (0.0039 inch)
^ If out of specification, resurface the cylinder block. The allowable amount of resurfacing is dependent on the amount of any cylinder head resurfacing. The resurfacing limit is [amount of cylinder head resurfacing] + [amount of cylinder head resurfacing] = 0.2 mm (0.008 inch).
Cylinder block height: 214.95 - 215.05 mm (8.4626 - 8.4665 inch)
INNER DIAMETER OF MAIN BEARING HOUSING
^ Install the main bearing caps with the main bearings removed, and tighten the bolts to the specified torque.
^ Using a bore gauge, measure the inner diameter of the main bearing housing.
Standard: 63.993 - 64.017 mm (2.5194 - 2.5203 inch)
^ If out of the standard, replace the cylinder block and main bearing caps as an assembly.
NOTE: These components cannot be replaced as a single unit, because they were processed together.
PISTON-TO-CYLINDER BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. The X axis is in the longitudinal direction of the engine.
If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
Out-of-round (Difference between X and Y): limit 0.015 mm (0.0006 inch)
Taper (Difference between A and C): limit 0.015 mm (0.0006 inch)
2. Check for scratches and seizure. If seizure is found, hone it.
^ If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter.
Piston diameter A: Refer tom Specifications.
Measuring point a (Distance from the top): 41.0 mm (1.61 inch)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance at B: 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
^ The piston-to-bore clearance is measured at the B level in the cylinder as shown.
5. Determine piston oversize according to amount of cylinder wear.
Oversize pistons are available for service.
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter A.
Rebored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 inch)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted after boring.
8. Cut cylinder bores.
^ When any cylinder needs boring, all other cylinders must also be bored.
^ Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 inch) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
^ Measurement should be done after cylinder bore cools down.
BEARING CLEARANCE
^ Use either of the following two methods, however method A gives more reliable results and so is the preferred method.
Method A (Using Bore Gauge and Micrometer)
Main Bearing
1. Set the main bearings in their proper positions on the cylinder block and the main bearing cap.
2. Install the main bearing caps and bearing beam to the cylinder block. Tighten all bolts in the numerical order as specified.
3. Measure the inner diameters A of each main bearing as shown.
4. Measure the outer diameters Dm of each crankshaft main journal as shown.
5. Calculate the main bearing clearance.
Main bearing clearance = A - Dm
Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 inch)
Limit: 0.065 mm (0.0026 inch)
^ If it exceeds the limit, replace the bearing.
^ If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use an undersized bearing.
^ When grinding the crankshaft journal, confirm that the L dimension in the fillet role is more than the specified limit.
L: 0.1 mm (0.004 inch)
6. If the crankshaft or the cylinder block is replaced with a new one, select thickness of the main bearings as follows:
a. The grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals. If measured diameter is out of the grade punched, decide suitable grade from available main bearings.
b. The grade number of each crankshaft main journal is punched on the crankshaft end. These numbers are punched in either Arabic or Roman numerals. If measured diameter is out of grade punched, decide the suitable grade from available main bearings.
c. Select the main bearing suitable thickness according to the following table:
Connecting Rod Bearing (Big End)
1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification.
3. Measure the inner diameter C of each connecting rod (big end) as shown.
4. Measure the outer diameter Dp of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 inch)
Limit: 0.070 mm (0.0028 inch)
6. If the calculated clearance exceeds the specified limit, replace the bearings.
7. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings.
8. If the crankshaft is replaced with a new one, select the connecting rod bearings according to the following table:
Connecting Rod Bearing Grade Number (Identification Color)
These numbers are punched in either Arabic or Roman numerals.
Method B (Using Plastigage)
^ Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
^ Cut a Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod nuts to the specified torque.
CAUTION: Never rotate the crankshaft.
^ Remove the connecting rod cap and bearings, and using the scale on the Plastigage bag, measure the Plastigage width.
NOTE: The procedure when the measured value exceeds the repair limit is same as that described in Method A (Using Bore Gauge and Micrometer).
CYLINDER BLOCK:
CYLINDER BLOCK