engine MAZDA 626 1987 Workshop Manual

16 OUTLINE
Thermometer (Dry)
Thermometer
(Dry & Wet)
76G16X-633
69G16X-024
DETERMINING THE RELATIVE HUMI-DITY: Read the temperatures of the dry- and v^et-bulb thermometers at the air inlet (evapo-rator inlet). Then bring them into mutual relation on the chart and determine the intersection, which is the relative humidity^ For exampie, if the dry-bulb temperature^ is 90° F. and the wet-bulb temper- ^ ature is 78° F, the relative humidity is ^ 60%.
DRV BUL8 TEMPERATURE
Performance Test
After finishing repairs, be sure to conduct a perfor-
mance test of the air conditioning system as follows.
Procedure
1. Connect the manifold gauge set. (Refer to page
16-8)
2. Run the engine and keep the engine speed at
1750 rpm.
3. Operate the air conditioner at MAX COOLING.
4. Open all windows and doors.
5. Insert a dry-bulb thermometer in the center of the
ventilator outlet.
6. Place a dry and wet thermometer close to the in-
let of the blower inlet.
7. The high pressure should be within 1374—1569
kPa (14.0—16.0 kg/cm2, 200—227 psi).
Note:
If the pressure is too high, pour water on the
condenser; if it is too low, cover the front sur-
face of the condenser.
8. The dry-bulb thermometer at the inlet should be
within 25—35°C (77—95°F).
Operate the air conditioning system in this condi-
tion until the conditions of the high and low pres-
sure gauges and thermometers are stabilized.
Reading the standard performance curve
1. Read the inlet temperature an get the relative hu-
midity from the psychrometric chart.
2. Read the cool air temperature at the air outlet.
3. Determine the difference between the inlet and out-
let dry-bulb temperature.
4. For example, when the difference is 17°C (30.6°F)
and the relative humidity is 60%:

If
the closing point is the upper part of the line, cool-
ing performance is satisfactory.
76G16X-634
READING THE GRAPH: After reading the temperatures of the wet-and dry-bulb thermometers at the evapo-rator air inlet, the relative humidity (%} can be determined Example: If the dry- and wet-bulb temperatures at the evaporator air inlet are 25°
C
and 19 5°C respectively, find the point of intersection of the dotted lines in the graph, which is

• i
•.p-I--!1. fi -GL^TIULB ': "'.L .T.L CL
16—12

COMPRESSOR 16
69G16X-026
M10X1.25^45
Low-pressure x pressure
hose hose Compressor
COMPRESSOR
ON-VEHICLE INSPECTION
1. Connect the manifold gauge set.
2. Run the engine at 1,500 rpm.
3. Check the compressor flow:
a) High pressure is not low and low pressure is not
higher than normal.
b) Metallic sound.
c) Check to be sure that the high-pressure and low-
pressure gauges show the same value immedi-
ately after the air conditioner is switched OFF.
If both gauges show the same value immediate-
ly, it can be assumed that the gasket or the valve
inside the compressor is damaged.
4. Stop the engine.
5. Check the shaft seal and others for leakage.
6. Inspect the drive plate pulley magnetic clutch for
signs of oil.
7. Check the clearance between the drive plate and
pulley. (Refer to page 16—21.)
If any of the above checks reveal faults, repair the
compressor or magnetic clutch.
76G16X-635
Bracket No.2 Adjusting Bolt Bracket

, ,shaft

' stay _ M8XI. 25^20 MIO X 1.25 Compressor
69G16X-028
REMOVAL OF COMPRESSOR
1. Perform the Oil Return Operation. (See below.)
2. Disconnect the battery ground cable.
3. Disconnect the clutch lead wire from the wiring
harness.
4. Discharge the refrigerant from the refrigeration
system.
5. Disconnect the two flexible hoses. Plug the open
fittings immediately to keep moisture out of the
system.
6. Loosen the drive belt.
7. Remove the compressor mounting bolts and the
compressor.
Bracket No.1 M
to* 1.25

^Compressor
MIOxl. 25^110 MIOxl. 25^125
Oil Return Operation
1. If the refrigerant level is low, charge the system to
the specified amount.
2. Run the engine and air conditioner at idle and at
maximum cooling for at least 20 minutes.
76G16X-636
16—13

RECEIVER-DRIER 16
RECEIVER-DRIER
ON-VEHICLE INSPECTION
1. Use a leak detector to check the sight glass, the
fusible plug, and the fittings for leakage.
Repair or replace, if necessary.
2. Check the receiver-drier for clogging.
a) Run the engine at fast idle with the air conditioner
on.
b) Check both inlet and outlet temperatures.
If there is a great difference between the two tem-
peratures, replace the receiver-drier.
76G16X-622
Receiver-drier
Condenser bolt
76G16X-638
REMOVAL OF RECEIVER-DRIER
1. Discharge the air conditioning system.
(Refer to page 16—9)
2. Disconnect the two liquid line pipes from the
receiver-drier.
Note:
Plug the open fittings immediately to keep
moisture out of the system.
3. Remove the receiver-drier from the bracket.
INSTALLATION OF RECEIVER-DRIER
1. Install the receiver-drier onto the bracket.
Note:
Do not remove the blind plugs until ready for
connection.
2. Connect the two liquid line pipes to the
receiver-drier.
Tightening torque:
15—25 N m (1.5—2.5 m-kg, 11—18 ft-lb)
3.
If
the receiver-drier is replaced with a new one, add
compressor oil to the compressor.
Compressor oil: 10 cc (0.61 cu in)
16-25

16 COOLING UNIT
COOLING UNIT
ON-VEHICLE INSPECTION OF EXPANSION
VALVE
1. Connect the manifold gauge set to the gauge fit-
tings on the low- and high-pressure pipes.
2. Operate the engine at 1,500 rpm and the air con-
ditioner at MAX. COOLING.
3. Check the low and high pressures.
Normal pressures are:
Low: 197—294 kPa
(2—3 kg/cm2, 28—43 psi)
High: 1472—1765 kPa
(15—18 kg/cm2, 210—260 psi)
If pressure is not as specified, replace the expansion
valve.
76G16X-623
REMOVAL OF COOLING UNIT
1. Disconnect the battery ground cable.
2. Discharge the air conditioning system. (Refer to page 16—9.)
3. Disconnect the suction low-pressure pipe from the evaporator unit outlet fitting.
4. Disconnect the liquid line pipe from the evaporator unit inlet fitting.
Note:
Plug all open fittings immediately to keep moisture out of the system.
5. Remove the grommets from the expansion valve.
6. Remove the instrument lower panel and the glove box.
7. Remove the sealing plates from both sides of the cooling unit.
8. Disconnect the A/C wiring harness from the evaporator unit.
9. Remove the drain hose from the cooling unit.
10. Remove the two nuts and the cooling unit.
76G16X-624
16-26

30
TECHNICAL DATA
MEASUREMENT 30— 2
ENGINE (SOHC) 30— 2
ENGINE (DOHC) 30— 8
ENGINE (DIESEL) 30—11
LUBRICATION SYSTEM (GASOLINE) 30—14
LUBRICATION SYSTEM (DIESEL) 30—15
COOLING SYSTEM (GASOLINE) 30—16
COOLING SYSTEM (DIESEL) 30—17
FUEL AND EMISSION CONTROL SYSTEM
(CARBURETOR) 30—18
FUEL AND EMISSION CONTROL SYSTEM
(FUEL INJECTION FE) 30—20
FUEL AND EMISSION CONTROL SYSTEM
(FE DOHC) 30—21
FUEL AND EMISSION CONTROL SYSTEM
(DIESEL) 30—22
ENGINE ELECTRICAL SYSTEM 30—23
CLUTCH 30—25
MANUAL TRANSAXLE 30—26
AUTOMATIC TRANSAXLE
(ELECTRONICALLY CONTROLLED AND
4-SPEED) 30—27
AUTOMATIC TRANSAXLE (3-SPEED) 30—33
FRONT AND REAR AXLES 30—36
STEERING SYSTEM 30—36
BRAKING SYSTEM 30—37
WHEEL AND TIRE 30—38
SUSPENSION 30—38
BODY ELECTRICAL SYSTEM 30—39
STANDARD BOLT AND NUT
TIGHTENING TORQUE 30—40
76G30X-001

30 TECHNICAL DATA
0. MEASUREMENT
Item Engine model Coupe/MX-6 Sedan Hatchback

Overall length mm (in) 4,450 (175.2) 4,515 (177.8) 4,515 (177.8)
Overall width mm (in) 1,690 (66.5) 1,690 (66.5) 1,690 (66.5)
Overall height (14 inch/13 inch) mm (in) 1,360 (53.5)/1,345 (52.9) 1,410 (55 5)/1,395 (54.9) 1,375 (54.1)/1,360 (53 5)
Wheel base mm (in) 2,515 (99.0) 2,575 (101.4) 2,575 (101.4)
Tread (14 inch/13 inch)
mm (in)
Front 1,455 (57.3)/1,460 (57.5) 1,455 (57.3)/(1,460 (57.5) 1,455 (57.3)/1,460 (57.5) Tread (14 inch/13 inch)
mm (in)
Rear 1,465 (57.7)/1,455 (57.3) 1,465 (57.7)/1,455 (57.3) 1,465 (57 7)/1,455 (57 3)
1
A. ENGINE (SOHC)
12-valve
— Engine model Item FE 12-valve
~vpe
Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinders
Type
of
combustion chamber Pentroof
Valve system OHC, belt-driven
Bore
x
Stroke
mm (in)
86.0
x
86.0 (3.39
x
3.39)
Total piston displacement
cc
(cu
in)
1,998 (121.9)
Compression ratio 9.5
: 1

Compression pressure
kPa (kg/cm2, psi)-rpm
Standard 1,422 (14.5, 206)—280
Compression pressure
kPa (kg/cm2, psi)-rpm
Minimum 996 (10.2, 144)—280 Compression pressure
kPa (kg/cm2, psi)-rpm Maximum difference
between cylinders 196 (2.0,
28)

Valve timing
IN
Open
BTDC 14°
Valve timing
IN Close ABDC 56° Valve timing
EX Open BBDC 69° Valve timing
EX Close ATDC 13°
Valve clearance
mm (in)
IN 0; Maintenance free Valve clearance
mm (in)
EX 0; Maintenance free

Cylinder head

Heiaht
mm (inl
91.95-92.05 (3.620-3.624)
Distortion
mm (inl
Maximum 0.15 (0.006)
Grinding limit
mm (in)
Maximum 0.20 (0.008)

Valve and valve auide

Valve head diameter
mm (in)
IN 32.4-32.6 (1.276—1.283) Valve head diameter
mm (in)
EX 33.9-34.1 (1.335-1.343)
Valve head thickness (margin)
mm (in)
IN 0.8-1.2 (0.031—0.0471 Valve head thickness (margin)
mm (in)
EX 1.3—1.7 (0.051-0.067)
Valve face angle IN 45° Valve face angle EX 45°
Valve length
mm (in)

IN Standard 115.81 (4.55941
Valve length
mm (in)

IN Minimum 115.31 (4.5398) Valve length
mm (in)
cv Standard 116.21 (4.5752)
Minimum 115.71 (4.55551
Valve stem diameter
mm (in)
IN 6.970-6.985 (0.2744-0.2750) Valve stem diameter
mm (in)
EX 6.965-6.980 (0.2742-0.27481
Guide inner diameter
mm (in)
IN 7.01-7.03 (0,2760-0.2768) Guide inner diameter
mm (in)
EX 7.01-7.03 (0.2760-0.27681
Valve stem
to
guide clearance
mm (in)

IN 0.025-0.060 (0.0010-0.0024)
Valve stem
to
guide clearance
mm (in)
EX 0.030-0.065 (0.0012—0.0026) Valve stem
to
guide clearance
mm (in)

Maximum 0.20 (0.00791
Guide projection (Height "A")
mm (in)
19.8-20.3 (0.780-0.799)

30—2

30 TECHNICAL DATA
Item Engine model FE 12-valve

Top 0.20—0.35 (0.008-0.0138)
End gap measured
in
cylinder
mm
(in) Second 0.15—0.30 (0.006-0.012) End gap measured
in
cylinder
mm
(in) Oil (rail) 0.20-0.70 (0.008-0.0276)
Maximum 1.0 (0.039)
Top 1.52-1.54 (0.0598-0.0606)
Ring groove width
in
piston mm (in) Second 1.52-1.54 (0.0598-0.0606)
Oil 4.02-4.04 (0.1583-0.1591)
Top 0.03—0.07 (0.0012—0.0028) Clearance
ot
piston ring
to
ring Second 0.03—0.07 (0.0012-0.0028)
Maximum 0.15(0.006)

Piston pin

Diameter mm (in) 21.974-21.980 (0.8651-0.8654)
Interference
in
connecting
rod
mm (in) 0.013-0.037 (0.0005-0.0015)
Piston
to
piston pin clearance mm (in) 0.008-0.024 (0.0003—0.0009)
Installation pressure N (kg,
lb)
4,900-14,700 (500-1,500, 1,100-3,300)

Connecting rod and connecting rod bearing

Length (Center
to
center) mm (in) 151.95—152.05 (5.982—5.986)
Twisting and bending mm (in) 0.06 (0.0024) max.
Small end bore mm (in) 21.943—21.961 (0.8640-0.8646)
Big end bore mm (in) 54.002-54.017 (2.1261—2.1266)
Big end width mm (in) 26.838-26.890 (1.0566—1.0587)
Connecting rod side clearance
mm
(in) Standard 0.110-0.262 (0.004-0.010) Connecting rod side clearance
mm
(in) Maximum 0.30 (0.012)

Crankshaft

Crankshaft runout mm (in) Maximum 0.03 (0.0012)
Standard size 59.937-59.955 (2.3597—2.3604)
0.25 (0.010) Standard 59.693-59.711 (2.3501-2.3508)
Main journal diameter mm (in)
undersize No.3 59.687-59.705 (2.3499-2.3506) Main journal diameter mm (in) 0.50 (0.020) No. 1,2,4,5 59.443-59.461 (2.3403-2.3410) Main journal diameter mm (in) undersize No.
3
59.437-59.455 (2.3400-2.3407)
0.75 (0.030) No. 1,2,4,5 59.193-59.211 (2.3304-2.3311)
undersize No.
3
59.187-59.205 (2.3302-2.3309)
Main journal taper and out-of-round mm (in) Maximum 0.05 (0.0020)
Standard 50.940-50.955 (2.0055-2.0061)
Crankpin diameter 0.25 (0.010) undersize 50.690—50.705 (1.9957-1.9963)
mm (in) 0.50 (0.020) undersize 50.440-50.455 (1.9858-1.9864)
0.75 (0.030) undersize 50.190-50.205 (1.9760-1.9766)
Crankpin taper and out-of-round
mm (in)
Maximum 0.05 (0.0020)

Main bearing

No. 1,2,4,5 Standard 0.025-0.043 (0.0010—0.0017)
Main journal bearing
oil
No. 1,2,4,5 Maximum 0.08 (0.0031) clearance
mm
(in) No.
3
Standard 0.031—0.049 (0.0012—0.0019) No.
3
Maximum 0.08 (0.0031)
Available undersize bearing mm fin} 0.25 (0.010), 0.50 (0.020), 0.75 (0.030)

Crankpin bearing

Crankpin bearing
oil
clearance
mm
(in) Standard 0.027-0.067 (0.0011-0.0026) Crankpin bearing
oil
clearance
mm
(in) Maximum 0.10 (0.0039)
Available undersize bearina mm (in) 0.25 (0.010), 0.50 (0.020), 0.75 (0.030)

Thrust bearing (center main bearing)

Crankshaft end play mm (in) Standard 0.08-0.18 (0.0031-0.0071) Crankshaft end play mm (in) Maximum 0.30 (0.0118)
Standard 27.94-27.99 (1.100-1.102)
Bearing width
mm (in)
0.25 (0.010) oversize 28.04-28.09 (1.104-1.106) Bearing width
mm (in)
0.50 (0.020) oversize 28.12-28.17 (1.107-1.109)
0.75 (0.030) oversize 28.20—28.25 (1.110—1.112)

30—4

TECHNICAL DATA 30
" Engine model Item FE 12-valve
Timing belt

Belt deflection
mm
(in)/98
N
(10 kg,
22 lb)
5.5—6.5 (0.22-0.26)

8-valve
Engine model
Item -••--.
FE 8-valve F8
F6
Engine model
Item -••--. ECE Middle
East
General
ECE General F6

Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinders
Type
of
combustion chamber Multispherical
Valve system OHC, belt-driven
Bore
x
Stroke
mm
(in) 86.0
x
86.0 (3.39
x
3.39) 86.0
x
77.0
(3.39
x
3.03)
81.0
x
77.0 (3.19
x
3.03)
Total piston displacement
cc
(cu
in)
1,998 (121.9) 1,789 (109.1) 1,587 (96.8)
Compression ratio 8.6
: 1
9.0
: 1

Compression pressure kPa (kg/cm2, psi)-rpm
Standard 1,275 (13.0, 185)—270 1,128 (11.5, 164)—270
Compression pressure kPa (kg/cm2, psi)-rpm Minimum 893 (9.1, 129)—270 790 (8.1, 114)—270 Compression pressure kPa (kg/cm2, psi)-rpm Maximum difference
between cylinders 196 (2.0,
28)

Valve timing
IN Open BTDC 16° 20° 17°
Valve timing
IN Close ABDC 54° 65° 56° Valve timing
EX Open BBDC 54° 65° 64° Valve timing
EX Close ATDC 16° 20° 15°
Valve clearance
mm
(in) IN 0.30 (0.012) Valve clearance
mm
(in) EX 0.30 (0.012)

Cylinder head

Height
mm (in)
91.95-92.05 (3.620-3.624)
Distortion
mm
(in) Maximum 0.15 (0.006)
Grinding limit mm (in) Maximum 0.20 (0.008)

Valve and valve guide

Valve head diameter
mm
(in) IN 43.9-44.1 (1.728-1.736) Valve head diameter
mm
(in) EX 35.9-36.1 (1.413-1.421)
Valve head thickness (margin)
mm
(in) IN 0.8—1.2 (0.031-0.047) Valve head thickness (margin)
mm
(in) EX 1.3-1.7 (0.051-0.067)
Valve face angle IN 45° Valve face angle EX 45°
Valve length
mm
(in)
IN Standard 111.89 (4.4051)
Valve length
mm
(in)
IN Minimum 111.39 (4.3854) Valve length
mm
(in)
EX Standard 111.69 (4.3972) Valve length
mm
(in)
EX Minimum 111.19 (4.3776)
Valve stem diameter
mm
(in) IN 8.030-8.045 (0.3161-0.3167) Valve stem diameter
mm
(in) EX 8.025-8.040 (0.3159-0.3165)
Guide inner diameter
mm
(in) IN 8.07-8.09 (0.3177-0.3185) Guide inner diameter
mm
(in) EX 8.07-8.09 (0.3177-0.3185)
Valve stem
to
guide clearance
mm
(in)
IN 0.025-0.060 (0.0010-0.0024)
Valve stem
to
guide clearance
mm
(in) EX 0.030-0.065 (0.0012-0.0026) Valve stem
to
guide clearance
mm
(in)
Maximum 0.20 (0.0079)
Guide projection (Height "A")
mm
(in) 19.1-19.6 (0.752-0.772)

30-5

30 TECHNICAL DATA
Engine model FE 8-valve
Item ECE Middle East General
F8 F6
Valve seat

Seat angle IN 45° Seat angle EX 45°
Seat contact width mm (in) IN 1.2—1.6 (0.047-0.063) Seat contact width mm (in) EX 1.2-1.6 (0.047-0.063)
Seat sinking (Measure valve protruding length)
mm (in)
IN Standard 46.5 (1.831) Seat sinking (Measure valve protruding length)
mm (in)
IN Maximum 48.0 (1.890) Seat sinking (Measure valve protruding length)
mm (in) EX Standard 46.5 (1.831)
Seat sinking (Measure valve protruding length)
mm (in) EX Maximum 48.0 (1.890)

Valve spring

Free length mm (in)
Outer
Inner
Standard
Minimum
51.5(2.028)

Standard
44.0 (1.732)

Minimum
43.3 (1.705)
51.2 (2.016)
52.0 (2.047)

50.6 (1.992)
51.5 (2.028)

45.7 (1.799)
44.0 (1.732)

437 (1.720)1
43.3 (1.705)
Out-of-square mm (in) Maximum 1.8 (0.071)
Setting load/height
N
(kg, lb)/mm
(in)
Outer
128(13.1,29) 136.5
(1
44)

Inner
189 (19,2, 42) 141 (1.61)
124 (12.7, 28) 136.5
(1
44)
193 (19.6,43) 141 (1.61)

128 (13.1, 29)/36.5 (1.44)
189 (19.2, 42)/41 (1.61)

Camshaft

Cam lobe height
mm (in)

IN
EX
Standard
Minimum
Standard
Minimum
38.107-38.207 (1.5003-1.5042)
37.957 (1.4944)
38.110-38.210 (1.5004-1.5043)
37.960 (1.4945)
Journal diameter
mm (in)

Front and Rear (No.
1,5)
31.940-32.035 (1.2575-1.2612)
Center (No. 2,3,4)
Out-of-round Maximum
31.910-32.065 (1.2563-1.2624)
0.05 (0.002)
Camshaft bearing
oil
clearance
mm (in)

Front and Rear (No.
1,5)
0.035-0.085 (0.0014-0.00331
Center (No. 2,3,4) 0.065-0.115 (0.0026—0.0045)
Maximum 0.15 (0.0059)
Camshaft runout mm (in) Maximum 0.03 (0.00121
Camshaft end play mm (in) Standard 0.08—0.16 (0.003—0.006)

Maximum 0.20 (0.008)
Rocker arm and rocker arm shaft

Rocker arm inner diameter mm (in) 16.000-16.027 (0.6299-0.6310)
Rocker arm shaft diameter mm (in) 15.966-15.984 (0.6286-0.6293)
Rocker arm
to
shaft clearance
mm (in)
Standard 0.016—0.061 (0.0006-0.0024)
Maximum 0.10 (0.004)

Cylinder block

Heiaht mm
fin)
289.0 (11.38) 268.5 (10.57)
Distortion mm (in) Maximum 0.15 (0.006)
Grindina limit mm (in)
0.20 (0.008)

Cylinder bore diameter
mm (in)
Standard 86.000—86.019 (3.3858—3.3866)
0.25 (0.010) oversize 86.250-86.269 (3.3957-3.3964)
0.50 (0.020) oversize 86.500-86.519 (3.4055-3.4062)
0.75 (0.030) oversize
1.00 (0.039) oversize

81.000-
(3.1890-
-81.019 -3.1897)
81.250-(3.1988-
-81.269
-3.1996) 81.500-(3.2087-
-81.519 -3.2094)
81.750-(3.2185-
-81.769
-3.2192)

82.000-

(3.2283-
-82.019
-3.2291)
Cylinder bore taper and out-of-round mm (in) Maximum 0.019 (0.0007)

Piston

Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below
oil
ring groove
mm (in)
Standard 85.944-85.964 (3.3836—3.3844) 80.944-80.964
(3.1868—3.1876) Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below
oil
ring groove
mm (in)
0.25 (0.010) oversize 86.194—86.214 (3.3935—3.3942) 81.194—81.214
(3.1966-3.1974)
Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below
oil
ring groove
mm (in) 0.50 (0.020) oversize 86.444-86.464 (3.4033-3.4041) 81.444-81.464
(3.2065-3.2072)

30—6

TECHNICAL DATA 30
—Engine model
Item -
FE 8-valve
F8 F6
—Engine model
Item -
ECE Middle East General
F8 F6

0.75 (0.030) oversize
—
81.694—81.714
(3.2163-3.2171)
1.00 (0.039) oversize
—
81.944—81.964 (3.2261-3.2269)
Piston and cylinder clearance
mm
(in) Standard 0.036-0.075 (0.0014—0.0030) Piston and cylinder clearance
mm
(in) Maximum 0.15 (0.0059)

Piston ring

Thickness
mm
(in) Top 1.47-1.49 (0.0579-0.0587) Thickness
mm
(in) Second 1.47-1.49 (0.0579—0.0587)
End gap measured
in
cylinder
mm (in)

Top 0.20—0.35 (0.008—0.0138)
End gap measured
in
cylinder
mm (in)
Second 0.15-0.30 (0.006-0.012) End gap measured
in
cylinder
mm (in)
Oil (rail) 0.20—0.70 (0.008—0.0276) End gap measured
in
cylinder
mm (in)

Maximum 1.0 (0.039)
Ring groove width
in
piston
mm
(in)
Top 1.52—1.54 (0.0598-0.0606)
Ring groove width
in
piston
mm
(in) Second 1.52-1.54 (0.0598-0.0606) Ring groove width
in
piston
mm
(in)
Oil 4.02-4.04 (0.1583-0.1591)
Clearance
of
piston ring
to
ring
groove
mm
(in)
Top 0.03-0.07 (0.0012-0.0028) Clearance
of
piston ring
to
ring
groove
mm
(in) Second 0.03-0.07 (0.0012-0.0028) Clearance
of
piston ring
to
ring
groove
mm
(in) Maximum 0.15 (0.006)

Piston pin

Diameter
mm
(in) 21.974—21.980 (0.8651—0.8654)
Interference
in
connecting
rod mm
(in) 0.013—0.037 (0.0005—0.0015)
Piston
to
piston pin clearance
mm
(in) 0.008—0.024 (0.0003-0.0009)
Installation pressure
N
(kg,
lb)
4,900—14,700 (500—1,500, 1,100—3,300)

Connecting rod and connecting rod bearing

Length (Center
to
center)
mm
(in) 151.95-152.05 (5.982-5.986) 135.95—136.05
(5.352-5.356)
Twisting and bending
mm
(in) 0.06 (0.0024) max.
Small end bore
mm
(in) 21.943-21.961 (0.8640-0.8646)
Big end bore
mm
(in) 54.002-54.017 (2.1261—2.1266)
Bia end width
mm
(in) 26.838-26.890 (1.0566—1.0587)
Connecting rod side clearance
mm
(in) Standard 0.110-0.262 (0.004—0.010) Connecting rod side clearance
mm
(in) Maximum 0.30 (0.012)

Crankshaft

Crankshaft runout mm (in)
I
Maximum 0.03 (0.0012)
Main journal diameter
mm (in)
Standard size 59.937-59.955 (2.3597—2.3604)
Main journal diameter
mm (in)
0.25 (0.010) undersize
Standard 59.693—59.711 (2.3051—2.3508)
Main journal diameter
mm (in)
0.25 (0.010) undersize No.
3
59.687—59.705 (2.3499-2.3506) Main journal diameter
mm (in) 0.50 (0.020) undersize
No. 1,2,4,5 59.443-59.461 (2.3403—2.3410) Main journal diameter
mm (in) 0.50 (0.020) undersize No.
3
59.437-59.455 (2.3400—2.3407)
Main journal diameter
mm (in)
0.75 (0.030)
undersize
No. 1,2,4,5 59.193-59.211 (2.3304—2.3311)
Main journal diameter
mm (in)
0.75 (0.030)
undersize No.
3
59.187—59.205 (2.3302—2.3309)
Main journal taper and out-of-round mm (in) Maximum 0.05 (0.0020)
Crankpin diameter mm (in)
Standard 50.940-50.955 (2.0055-2.0061)
Crankpin diameter mm (in)
0.25 (0.010) undersize 50.690-50.705 (1.9957-1.9963) Crankpin diameter mm (in) 0.50 (0.020) undersize 50.440-50.455 (1.9858-1.9864) Crankpin diameter mm (in)
0.75 (0.030) undersize 50.190—50.205 (1.9760-1.9766)
Crankpin taper and out-of-round
mm
(in) Maximum 0.05 (0.0020)

Main bearlna

Main journal bearing
oil
clearance
mm
(in)
No. 1,2,4,5 Standard 0.025-0.043 (0.0010-0.0017)
Main journal bearing
oil
clearance
mm
(in)
No. 1,2,4,5 Maximum 0.08 (0.0031) Main journal bearing
oil
clearance
mm
(in) No.
3
Standard 0.031—0.049 (0.0012—0.0019)
Main journal bearing
oil
clearance
mm
(in) No.
3
Maximum 0.08 (0.0031)
Available undersize bearina
mm
(in) 0.25 (0.010), 0.50 (0.020), 0.75 (0.030)

Crankpin bearing

Crankpin bearing
oil
clearance
mm
(in) Standard 0.027-0.067(0.0011 -0.0026) Crankpin bearing
oil
clearance
mm
(in) Maximum 0.10 (0.0039)
Available undersize bearing
mm
(in) 0.25 (0.010), 0.50 (0.020), 0.75 (0.030)

30-7