Service Data
Cylinder Block Warpage
Using a precision straight edge and feeler gauge, measure the surface which is in contact with the cylinder head gasket for 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 75.000 to 75.133 mm (2.9528 to 2.9580 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 center line, and at a position 27 mm (1.06 inch) from the top of the piston head.
Piston diameter 74.945 to 74.955 mm (2.9506 to 2.9510 inch)
Using a caliper gauge, measure the piston pin hole diameter of the piston.
Piston pin hole diameter at 20°C (68°F) 18.013 to 18.016 mm (0.7092 to 0.7093 inch)
Piston Oil Clearance
Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance 0.045 to 0.068 mm (0.0018 to 0.0027 inch)
Maximum oil clearance 0.08 mm (0.0032 inch)
Piston Pin Oil Clearance
Piston pin diameter 18.001 to 18.004 mm (0.7087 to 0.7088 inch)
Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance 0.009 to 0.015 mm (0.0004 to 0.0006 inch)
Maximum oil clearance 0.050 mm (0.0020 inch)
Ring Groove Clearance
Ring Standard mm (in.)
No.1 0.03 to 0.07 mm (0.0012 to 0.0028 inch)
No.2 0.02 to 0.06 mm (0.0008 to 0.0024 inch)
Oil 0.02 to 0.06 mm (0.0008 to 0.0024 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
Connecting Rod Thrust Clearance
Standard thrust clearance 0.16 to 0.36 mm (0.0063 to 0.0142 inch)
Maximum thrust clearance 0.36 mm (0.0142 inch)
Connecting Rod Oil Clearance
Standard oil clearance 0.016 to 0.040 mm (0.0006 to 0.0016 inch)
Maximum oil clearance 0.06 mm (0.0024 inch)
Connecting Rod Sub-Assembly
Using a rod aligner and feeler gauge, check the connecting rod alignment.
Check for misalignment.
Maximum misalignment 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
Maximum twist 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
Connecting rod inside diameter 17.965 to 17.985 mm (0.7073 to 0.7081 inch)
Connecting Rod Bolt
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 6.6 to 6.7 mm (0.260 to 0.264 inch)
Maximum diameter: 6.4 mm (0.252 inch)
If the diameter is less than minimum, replace the bolt.
Crankshaft
Standard thrust clearance 0.09 to 0.19 mm (0.0035 to 0.0075 inch)
Maximum thrust clearance 0.30 mm (0.0118 inch)
Crankshaft Circle Runout
Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the crankshaft.
Main Journal Diameter
Diameter 45.988 to 46.000 mm (1.8106 to 1.8110 inch)
Maximum taper and distortion 0.02 mm (0.0008 inch)
Crank Pin
Diameter 39.992 to 40.000 mm (1.5745 to 1.5748 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 7.2 mm (0.283 inch)
Crankshaft Timing Sprocket and Chain
Wrap the chain around the timing sprocket.
Using vernier calipers, measure the timing sprocket diameter with the chain wrapped.
Standard sprocket diameter (w/ chain) 51.72 mm (2.0362 inch)
Minimum sprocket diameter (w/ chain) 50.5 mm (1.988 inch)
NOTICE: When measuring the diameter, vernier calipers must be in contact with the chain roller.
If the diameter is less than minimum, replace the chain and crankshaft.