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Engine Unit

ENGINE UNIT - SERVICE DATA

Connecting rod big end inside diameter Mark 1 56.000 to 56.006 mm (2.2047 to 2.2050 in.)
Mark 2 56.007 to 56.012 mm (2.2050 to 2.2052 in.)
Mark 3 56.013 to 56.018 mm (2.2052 to 2.2054 in.)
Mark 4 56.019 to 56.024 mm (2.2055 to 2.2057 in.)
Standard sized bearing center wall thickness Mark 1 1.481 to 1.484 mm (0.0583 to 0.0584 in.)
Mark 2 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
Mark 3 1.487 to 1.490 mm (0.0585 to 0.0587 in.)
Mark 4 1.490 to 1.493 mm (0.0587 to 0.0588 in.)
Standard crankshaft main journal diameter Mark 00 60.999 to 61.000 mm (2.4015 to 2.4016 in.)
Mark 01 60.998 to 60.999 mm (2.4015 to 2.4015 in.)
Mark 02 60.997 to 60.998 mm (2.4015 to 2.4015 in.)
Mark 03 60.996 to 60.997 mm (2.4014 to 2.4015 in.)
Mark 04 60.995 to 60.996 mm (2.4014 to 2.4014 in.)
Mark 05 60.994 to 60.995 mm (2.4013 to 2.4014 in.)
Mark 06 60.993 to 60.994 mm (2.4013 to 2.4013 in.)
Mark 07 60.992 to 60.993 mm (2.4013 to 2.4013 in.)
Mark 08 60.991 to 60.992 mm (2.4012 to 2.4013 in.)
Mark 09 60.990 to 60.991 mm (2.4012 to 2.4012 in.)
Mark 10 60.989 to 60.990 mm (2.4011 to 2.4012 in.)
Mark 11 60.988 to 60.989 mm (2.4011 to 2.4011 in.)
Standard upper bearing center wall thickness No. 1 and No. 4 journal Mark 1 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
Mark 2 2.503 to 2.506 mm (0.0985 to 0.0987 in.)
Mark 3 2.506 to 2.509 mm (0.0987 to 0.0988 in.)
Mark 4 2.509 to 2.512 mm (0.0988 to 0.0989 in.)
Mark 5 2.512 to 2.515 mm (0.0989 to 0.0990 in.)
Standard upper bearing center wall thickness No. 2 and No. 3 journal Mark 1 2.478 to 2.481 mm (0.0976 to 0.0977 in.)
Mark 2 2.481 to 2.484 mm (0.0977 to 0.0978 in.)
Mark 3 2.484 to 2.487 mm (0.0978 to 0.0979 in.)
Mark 4 2.487 to 2.490 mm (0.0979 to 0.0980 in.)
Mark 5 2.490 to 2.493 mm (0.0980 to 0.0981 in.)
Standard lower bearing center wall thickness No. 1 and No. 4 journal Mark 1 2.475 to 2.478 mm (0.0974 to 0.0976 in.)
Mark 2 2.478 to 2.481 mm (0.0976 to 0.0977 in.)
Mark 3 2.481 to 2.484 mm (0.0977 to 0.0978 in.)
Mark 4 2.484 to 2.487 mm (0.0978 to 0.0979 in.)
Mark 5 2.487 to 2.490 mm (0.0979 to 0.0980 in.)
Standard lower bearing center wall thickness No. 2 and No. 3 journal Mark 1 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
Mark 2 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
Mark 3 2.503 to 2.506 mm (0.0985 to 0.0987 in.)
Mark 4 2.506 to 2.509 mm (0.0987 to 0.0988 in.)
Mark 5 2.509 to 2.512 mm (0.0988 to 0.0989 in.)
Cylinder head set bolt Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum 10.70 mm (0.421 in.)
Chain Elongation Minimum 136.9 mm (5.390 in.)
No. 2 chain Elongation Minimum 137.6 mm (5.417 in.)
Crankshaft timing sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.417 in.)
Idle sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.417 in.)
Idle gear shaft Idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.)
Idle gear inside diameter 23.02 to 23.03 mm (0.9063 to 0.9067 in.)
Oil clearance Standard 0.02 to 0.043 mm (0.0001 to 0.0017 in.)
Maximum 0.093 mm (0.0037 in.)
No. 2 chain tensioner assembly Worn depth Maximum 0.9 mm (0.035 in.)
No. 3 chain tensioner assembly Worn depth Maximum 0.9 mm (0.035 in.)
Chain tensioner slipper Worn depth Maximum 1.0 mm (0.039 in.)
No. 1 chain vibration damper Worn depth Maximum 1.0 mm (0.039 in.)
No. 2 chain vibration damper Worn depth Maximum 1.0 mm (0.039 in.)
Cylinder head sub-assembly Standard warpage Cylinder head lower side 0.05 mm (0.0020 in.)
Intake side 0.08 mm (0.0031 in.)
Exhaust side 0.08 mm (0.0031 in.)
Maximum warpage 0.10 mm (0.0039 in)
Intake valve Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Margin thickness Standard 1.0 mm (0.039 in.)
Maximum 0.5 mm (0.0197 in.)
Overall length Standard 105.85 mm (4.1673 in.)
Maximum 105.35 mm (4.1476 in.)
Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Margin thickness Standard 1.0 mm (0.039 in.)
Maximum 0.5 mm (0.0197 in.)
Overall length Standard 110.40 mm (4.3464 in.)
Maximum 109.90 mm (4.3268 in.)
Inner compression spring Free length 51.70 mm (2.0354 in.)
Deviation Maximum 1.0 mm (0.039 in.)
Angle (reference) Maximum 2°
Intake valve guide bush Inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Maximum 0.08 mm (0.0031 in.)
Bush bore diameter Use STD 10.285 to 10.306 (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height 9.1 to 9.9 mm (0.3583 to 0.3898 in.)
Exhaust valve guide bush Inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum 0.10 mm (0.0039 in.)
Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 9.1 to 9.9 mm (0.3583 to 0.3898 in.)
Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.)
No. 1 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Standard cam lobe height Intake 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
Maximum cam lobe height Intake 44.168 mm (1.7389 in.)
Exhaust 44.191 mm (1.7398 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
No. 2 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Standard cam lobe height Intake 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
Maximum cam lobe height Intake 44.168 mm (1.7389 in.)
Exhaust 44.191 mm (1.7398 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
No. 3 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Standard cam lobe height Intake 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
Maximum cam lobe height Intake 44.168 mm (1.7389 in.)
Exhaust 44.191 mm (1.7398 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
No. 4 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Standard cam lobe height Intake 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
Maximum cam lobe height Intake 44.168 mm (1.7389 in.)
Exhaust 44.191 mm (1.7398 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
Ring pin for cylinder head sub-assembly Protrusion height 2.5 to 3.8 mm (0.098 to 0.150 in.)
Straight pin for cylinder head sub-assembly Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)
Connecting rod thrust clearance Standard 0.15 to 0.40 (0.0059 to 0.0157 in.)
Maximum 0.50 mm (0.0197 in.)
Connecting rod oil clearance Standard 0.045 to 0.067 (0.0018 to 0.0026 in.)
Maximum 0.070 mm (0.0028 in.)
Crankshaft thrust clearance Standard 0.04 to 0.24 (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Cylinder block warpage Maximum 0.07 mm (0.0028 in.)
Cylinder bush bore diameter Use standard 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Piston diameter Distance 9.1 mm (0.36 in.)
Standard 93.960 to 93.980 mm (3.6992 to 3.6999 in.)
Maximum 93.830 mm (3.6941 in.)
Piston oil clearance Standard 0.020 to 0.052 mm (0.0008 to 0.0020 in.)
Maximum 0.370 mm (0.0146 in.)
Connecting rod out-of alignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod twist Maximum 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
Piston pin hole inside diameter Mark A 21.998 to 22.001 mm (0.8661 to 0.8662 in.)
Mark B 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
Mark C 22.004 to 22.007 mm (0.8663 to 0.8664 in.)
Piston pin diameter Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 in.)
Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 in.)
Piston oil clearance Standard 0.020 to 0.052 mm (0.0008 to 0.0020 in.)
Maximum 0.370 mm (0.0146 in.)
Connecting rod bushing inside diameter Mark A 22.005 to 22.008 mm (0.8663 to 0.8665 in.)
Mark B 22.009 to 22.012 mm (0.8665 to 0.8666 in.)
Mark C 22.011 to 22.014 mm (0.8666 to 0.8667 in.)
Connecting rod bushing oil clearance Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum 0.03 mm (0.0012 in.)
Piston ring groove clearance No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
Piston ring end gap Standard No. 1 0.23 to 0.33 mm (0.0091 to 0.0130 in.)
No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum No. 1 0.40 mm (0.0157 in.)
No. 2 0.50 mm (0.0197 in.)
Oil (Side rail) 0.45 mm (0.0177 in.)
Connecting rod bolt diameter Standard 8.5 to 8.6 mm (0.335 to 0.339 in.)
Minimum 8.3 mm (0.327 in.)
Crankshaft bearing cap set bolt diameter Standard 10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Minimum 10.7 mm (0.4213 in.)
Crankshaft circle runout Maximum 0.06 mm (0.0024 in.)
Main journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crankshaft oil clearance Standard 0.045 to 0.067 mm (0.0018 to 0.0026 in.)
Minimum 0.070 mm (0.0028 in.)
Straight pin for cylinder block sub-assembly Protrusion height Pin A 6 mm (0.236 in.)
Pin B 23 mm (0.906 in.)
Pin C 11 mm (0.433 in.)
Pin D 9 mm (0.354 in.)
Tight plug for cylinder block Depth 0.2 to 1.2 mm (0.007 to 0.047 in.)
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