Cylinder Block Assembly: Specifications
CYLINDER BLOCKMachining Specifications
Surface warpage limit
(mating with cylinder head) 0.025 mm (0.00098 in.)
Surface grinding limit 0.1 mm (0.004 in.)
Standard height 201.0 mm (7.91 in.)
Inside diameter
STD
A 99.505 - 99.515 mm (3.9175 - 3.9179 in.)
B 99.495 - 99.505 mm (3.9171 - 3.9175 in.)
Taper
STD 0.015 mm (0.0006 in.)
Limit 0.050 mm (0.0020 in.)
Out-of-roundness
STD 0.010 mm (0.0004 in.)
Limit 0.050 mm (0.0020 in.)
Piston clearance
STD -0.010 - 0.010 mm (-0.0004 - 0.0004 in.)
Limit 0.030 mm (0.0012 in.)
Cylinder enlarging (boring) limit (dia.) 100.005 mm (3.937 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 (diameter) 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 (diameter) To 59.750 mm (2.3524 in.)
Crank pin outer diameter
STD 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 (2.0447 - 2.0453 in.)
0.25 mm (0.0098 in.) US 51.734 - 51.750 mm (2.0368 - 2.0374 in.)
Crank journal outer diameter
STD 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.)
0.25 mm (0.0098 in.) US 59.742 - 59.758 mm (2.3520 - 2.3527 in.)
Side clearance
STD 0.030 - 0.115 mm (0.0012 - 0.0045 in.)
Limit 0.25 mm (0.0098 in.)
Oil clearance
STD 0.010 - 0.030 mm (0.0004 - 0.0012 in.)
Limit 0.40 mm (0.0016 in.)
Main Bearing
Thickness at center
#1, #3
STD 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
STD 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.)
Piston
Outer diameter
STD
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 clearance
between piston pin and hole in piston
STD 0.004 - 0.008 mm (0.0002 - 0.0003 in.)
Limit 0.020 mm (0.0008 in.)
Degree of fit
Piston pin must be fitted into position with thumb at 20�C
(68�F).
Piston Ring
Piston ring gap
Top ring
STD
Outer circle side 0.20 - 0.25 mm (0.0079 - 0.0098 in.)
Inner circle side 0.20 - 0.30 mm (0.0079 - 0.0117 in.)
Limit 1.0 mm (0.039 in.)
Second ring
STD 0.37 - 0.52 mm (0.015 - 0.020 in.)
Limit 1.0 mm (0.039 in.)
Oil ring
STD 0.20 - 0.50 mm (0.0079 - 0.0197 in.)
Limit 1.5 mm (0.059 in.)
Clearance between piston ring and piston ring groove
Top ring
STD 0.04 - 0.08 mm (0.0016 - 0.0031 in.)
Limit 0.15 mm (0.0059 in.)
Second ring
STD 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
STD 0.070 - 0.330 mm (0.0028 - 0.0130 in.)
Limit 0.4 mm (0.016 in.)
Connecting Rod Bearing
Oil clearance
STD 0.017 - 0.045 mm (0.0007 - 0.0018 in.)
Limit 0.05 mm (0.0020 in.)
Thickness at center portion
STD 1.490 - 1.502 mm (0.0587 - 0.0591 mm)
0.03 mm (0.0012 in.) US 1.504 - 1.512 mm (0.0592 - 0.0595 in.)
0.05 mm (0.0020 in.) US 1.514 - 1.522 mm (0.0596 - 0.0599 in.)
0.25 mm(0.0098 in.) US 1.614 - 1.622 mm (0.0635 - 0.0639 in.)
Connecting rod bushing
Clearance between piston pin and bushing
STD 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 (diameter) 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 (diameter) To 59.750 mm (2.3524 in.)
Crank pin outer diameter
STD 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 (2.0447 - 2.0453 in.)
0.25 mm (0.0098 in.) US 51.734 - 51.750 mm (2.0368 - 2.0374 in.)
Crank journal outer diameter
STD 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.)
0.25 mm (0.0098 in.) US 59.742 - 59.758 mm (2.3520 - 2.3527 in.)
Side clearance
STD 0.030 - 0.115 mm (0.0012 - 0.0045 in.)
Limit 0.25 mm (0.0098 in.)
Oil clearance
STD 0.010 - 0.030 mm (0.0004 - 0.0012 in.)
Limit 0.40 mm (0.0016 in.)
Main bearing
Thickness at center
#1, #3
STD 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
STD 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 Bolt
Tighten 180 Nm (18.4 kgf-m, 132.8 ft. lbs.)