Service Data

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 88.500 to 88.513 mm (3.4843 to 3.4848 inch)
Maximum diameter 88.633 mm (3.4895 inch)
If the average diameter of the 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 the piston 30.3 mm (1.193 inch) from the piston head.
Piston diameter 88.439 to 88.449 mm (3.4819 to 3.4822 inch)
If the diameter is not as specified, replace the piston.

Piston Oil Clearance
Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance 0.051 to 0.074 mm (0.0020 to 0.0029 inch)
Maximum oil clearance 0.10 mm (0.0039 inch)





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 gap

Piston Pin Oil Clearance





Piston pin bore diameter 22.001 to 22.010 mm (0.8662 to 0.8665 inch)





Piston pin outer diameter 21.997 to 22.006 mm (0.8660 to 0.8664 inch)





Connecting rod small end bore diameter 22.005 to 22.014 mm (0.8663 to 0.8667 inch)





Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance 0.001 to 0.007 mm (0.00004 to 0.0003 inch)
Maximum oil clearance 0.013 mm (0.0005 inch)

Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance 0.017 mm (0.0007 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 7.2 to 7.3 mm (0.283 to 0.287 inch)
Maximum diameter 7.0 mm (0.276 inch)

Crankshaft
Maximum circle runout 0.03 mm (0.0012 inch)







Diameter (Reference)

Main Journal Diameter 54.988 to 55.000 mm (2.1649 to 2.1654 inch)
Main Journal Taper and Distortion
Maximum taper and distortion 0.003 mm (0.0001 inch)

Crank Pin Diameter 47.990 to 48.000 mm (1.8894 to 1.8898 inch)
Crank Pin Taper and Distortion:
Maximum taper and distortion 0.003 mm (0.0001 inch)

Crankshaft Bearing Cap Set Bolt
Standard diameter 7.5 to 7.6 mm (0.295 to 0.299 inch)
Minimum diameter 7.5 mm (0.295 inch)