Standards and Service Limits

Engine Block (4-door and 5-door (Japan made) models)

 2-8  

Item Measurement Qualification Standard or New Service Limit
Block Warpage of deck   0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)
Bore diameter   75.00-75.02 mm

(2.9528-2.9535 in.)

 75.07 mm (2.9555 in.)
Bore taper   - 0.05 mm (0.002 in.)
Reboring limit   - 0.5 mm (0.02 in.)
Piston Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt   74.98-74.99 mm

(2.9520-2.9524 in.)

 74.97 mm (2.9516 in.)
Clearance in cylinder   0.010-0.040 mm (0.0004-0.0016 in.) 0.05 mm (0.002 in.)
Ring groove width for D15Y3, D17A5 engines Top 1.020-1.030 mm (0.0402-0.0406 in.) 1.05 mm (0.041 in.)
Second 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in.)
Oil 2.805-2.820 mm (0.1104-0.1110 in.) 2.85 mm (0.112 in.)
Ring groove width for except D15Y3, D17A5 engines Top 1.020-1.030 mm (0.0402-0.0406 in.) 1.05 mm (0.041 in.)
Second 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in.)
Oil 2.005-2.020 mm (0.0789-0.0795 in.) 2.05 mm (0.08 in.)
Piston rings Ring-to-groove clearance for except D15Y3, D17A5 engines Top 0.035-0.055 mm (0.0014-0.0022 in.) 0.13 mm (0.005 in.)
Second 0.030-0.055 mm (0.0012-0.0022 in.) 0.13 mm (0.005 in.)
Ring-to-groove clearance for D15Y3, D17A5 engines Top 0.035-0.060 mm (0.0014-0.0024 in.) 0.13 mm (0.005 in.)
Second 0.030-0.055 mm (0.0012-0.0022 in.) 0.13 mm (0.005 in.)
Ring end gap for except D15Y3, D17A5 engines Top 0.15-0.30 mm (0.006-0.012 in.) 0.60 mm (0.024 in.)
Second 0.30-0.45 mm (0.012-0.018 in.) 0.60 mm (0.024 in.)
Oil 0.20-0.80 mm (0.008-0.031 in.) 0.90 mm (0.035 in.)
Ring end gap for D15Y3, D17A5 engine Top 0.15-0.30 mm (0.006-0.012 in.) 0.60 mm (0.024 in.)
Second 0.30-0.45 mm (0.012-0.018 in.) 0.60 mm (0.024 in.)
Oil 0.20-0.70 mm (0.008-0.028 in.) 0.80 mm (0.031 in.)
Piston pin O.D.   18.996-19.000 mm (0.7479-0.7480 in.) -
Pin-to-piston clearance   0.010-0.020 mm (0.0004-0.0008 in.) -
Connecting rod Pin-to-rod interference   0.016-0.036 mm (0.0006-0.0014 in.) -
Small-end bore diameter   18.96-18.98 mm (0.746-0.747 in.) -
Large-end bore diameter (Nominal) D14Z5 engine 43.0 mm (1.69 in.) -
D15Y2, D15Y3, D15Y4, D15Y5, D15Y6 engines 45.0 mm (1.77 in.) -
D16W7, D16W8, D17Z1, D17A1, D17A2, D17A5 engines 48.0 mm (1.89 in.) -
End play installed on crankshaft     0.15-0.30 mm (0.006-0.012 in.) 0.40 mm (0.016 in.)

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