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Cylinder HeadINFOID:0000000006289594
CYLINDER HEAD
Unit: mm (in)
VALVE DIMENSIONS
Unit: mm (in)
VA LV E G U I D E
Items Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 (4.97) —
PBIC0924E
Valve head diameter “D” Intake 36.6 - 36.9 (1.441 - 1.453)
Exhaust 31.2 - 31.5 (1.228 - 1.240)
Valve length “L” Intake 99.19 - 99.69 (3.9051 - 3.9248)
Exhaust 93.74 - 94.24 (3.6905 - 3.7102)
Valve stem diameter “d” Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Valve seat angle “ α” Intake
45°15 ′ - 45 °45 ′
Exhaust
Valve margin “T” Intake 1.1 (0.043)
Exhaust 1.3 (0.051)
Valve margin “T” limit 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
SEM188
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SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
*: Parts settings are for exhaust side only
VALVE SEAT
Unit: mm (in)
Items Standard Oversize (Service) [0.2 (0.008)]*
Va l v e g u i d e Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)*
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)*
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) Items Standard Limit
Valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.004)
Projection length “L” Intake 12.6 - 12.8 (0.496 - 0.504)
Exhaust 12.6 - 12.8 (0.496 - 0.504)
SEM950E
Items Standard
Oversize (Service) [0.5 (0.02)] *4
Cylinder head seat recess di-
ameter “D”Intake 38.000 - 38.016 (1.4961 - 1.4967) —
Exhaust 32.200 - 32.216 (1.2677 - 1.2683)
32.700 - 32.716 (1.2874 - 1.2880)*
4
Valve seat outer diameter “d”Intake 38.097 - 38.113 (1.4999 - 1.5005) —
Exhaust 32.280 - 32.296 (1.2709 - 1.2715)
32.780 - 32.796 (1.2906 - 1.2912)*4
Valve seat interference fitIntake 0.081 - 0.113 (0.0032 - 0.0044)
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Diameter “d1”*
1Intake 34.6 (1.362)
Exhaust 28.7 (1.130)
Diameter “d2”*
2Intake 35.9 - 36.4 (1.413 - 1.433)
Exhaust 30.3 - 30.8 (1.193 - 1.213)
Angle “ α1” 59 - 61°
PBIC2745E
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*1: Diameter made by intersection point of conic angles “
α1” and “ α2”
*
2: Diameter made by intersection point of conic angles “ α2” and “ α3”
*
3: Machining data
*
4: Parts settings are for exhaust side only
VALVE SPRING
Cylinder BlockINFOID:0000000006289595
CYLINDER BLOCK
Unit: mm (in)
Angle “ α2” 88°75 ′ - 90 °25 ′
Angle “ α3” 11 9 - 1 2 1°
Contacting width “W”*
3Intake 1.0 - 1.4 (0.039 - 0.055)
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Height “h” Intake 5.9 - 6.0 (0.232 - 0.236) —
Exhaust 5.9 - 6.0 (0.232 - 0.236)
4.95 - 5.05 (0.1949 - 0.1988)*
4
Depth “H” 6.0 (0.236)
ItemStandard
Intake Exhaust
Free height 47.28 mm (1.8614 in) 48.06 mm (1.8921 in)
Pressure Installation
166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
at 41.0 mm (1.614 in) 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
at 34.45 mm (1.3563 in)
Valve open 541 - 611 N (55.2 - 62.3 kg, 122 - 137 lb)
at 29.6 mm (1.165 in) 320.1 - 360.1 N (32.7 - 36.7 kg, 72 - 81 lb)
at 24.65 mm (0.9705 in)
Identification color Light green Light blue
Item Limit
Intake Exhaust
Out-of-square 2.1 mm (0.083 in) 2.0 mm (0.079 in)
Surface flatness Limit 0.1 (0.004)
Main bearing housing inner diameter Standard 68.944 - 68.968 (2.7143 - 2.7153)
Cylinder bore Inner diameter StandardGrade No. 1 98.000 - 98.010 (3.8583 - 3.8587)
Grade No. 2 98.010 - 98.020 (3.8587 - 3.8590)
Grade No. 3 98.020 - 98.030 (3.8590 - 3.8594)
Wear limit 0.2 (0.008)
Out-of-round Limit0.015 (0.0006)
Ta p e r 0.010 (0.0004)
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SERVICE DATA AND SPECIFICATIONS (SDS)
AVAILABLE PISTON
Unit: mm (in)
PISTON RING
Unit: mm (in)
Main bearing housing inner diameter grade (Without bearing)Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 4
Grade No. 768.944 - 68.945 (2.7143 - 2.7144)
68.945 - 68.946 (2.7144 - 2.7144)
68.946 - 68.947 (2.7144 - 2.7144)
68.947 - 68.948 (2.7144 - 2.7145)
68.948 - 68.949 (2.7145 - 2.7145)
68.949 - 68.950 (2.7145 - 2.7146)
68.950 - 68.951 (2.7146 - 2.7146)
68.951 - 68.952 (2.7146 - 2.7146)
68.952 - 68.953 (2.7146 - 2.7147)
68.953 - 68.954 (2.7147 - 2.7147)
68.954 - 68.955 (2.7147 - 2.7148)
68.955 - 68.956 (2.7148 - 2.7148)
68.956 - 68.957 (2.7148 - 2.7148)
68.957 - 68.958 (2.7148 - 2.7149)
68.958 - 68.959 (2.7149 - 2.7149)
68.959 - 68.960 (2.7149 - 2.7150)
68.960 - 68.961 (2.7150 - 2.7150)
68.961 - 68.962 (2.7150 - 2.7150)
68.962 - 68.963 (2.7150 - 2.7151)
68.963 - 68.964 (2.7151 - 2.7151)
68.964 - 68.965 (2.7151 - 2.7152)
68.965 - 68.966 (2.7152 - 2.7152)
68.966 - 68.967 (2.7152 - 2.7152)
68.967 - 68.968 (2.7152 - 2.7153)
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
Items Standard Oversize (S ervice) [0.2 (0.008)]
Piston skirt diameter “A” Grade No. 1 97.980 - 97.990 (3.8575 - 3.8579) —
Grade No. 2 97.990 - 98.000 (3.8579 - 3.8583) —
Grade No. 3 98.000 - 98.010 (3.8583 - 3.8587) —
Service — 95.680 - 95.710 (3.7669 - 3.7681)
Items Standard Limit
“H” dimension 40.0 (1.5748) —
Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)
PBIC0188E
Items Standard Limit
Side clearance Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.015 - 0.185 (0.0006 - 0.00728) 0.22 (0.0087)
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OPISTON PIN
Unit: mm (in)
CONNECTING ROD
Unit: mm (in)
*: After installing in connecting rod
CRANKSHAFT
End gap
Top 0.23 - 0.28 (0.0091 - 0.0110) 0.50 (0.0197)
2nd 0.50 - 0.65 (0.0197 - 0.0256) 0.84 (0.0331)
Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)
Items Standard Limit
Piston pin outer diameter 21.989 - 21.995 (0.8657 - 0.8659) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
Items Standard Limit
Center distance 154.45 - 154.55 (6.08 - 6.08) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Connecting rod bushing inner diameter* 22.000 - 22.006 (0.8661 - 0.8664) —
Connecting rod big end diameter (Without bearing) Grade No. A 57.000 - 57.001 (2.2441 - 2.2441)
Grade No. B 57.001 - 57.002 (2.2441 - 2.2442)
Grade No. C 57.002 - 57.003 (2.2442 - 2.2442)
Grade No. D 57.003 - 57.004 (2.2442 - 2.2442)
Grade No. E 57.004 - 57.005 (2.2442 - 2.2443)
Grade No. F 57.005 - 57.006 (2.2443 - 2.2443)
Grade No. G 57.006 - 57.007 (2.2443 - 2.2444)
Grade No. H 57.007 - 57.008 (2.2444 - 2.2444)
Grade No. J 57.008 - 57.009 (2.2444 - 2.2444)
Grade No. K 57.009 - 57.010 (2.2444 - 2.2445)
Grade No. L 57.010 - 57.011 (2.2445 - 2.2445)
Grade No. M 57.011 - 57.012 (2.2445 - 2.2446)
Grade No. N 57.012 - 57.013 (2.2446 - 2.2446)
Side clearance 0.20 - 0.40 (0.0079 - 0.0158) 0.40 (0.0157)
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SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
Main journal diameter. “Dm” grade
(No. 1 and 5 journal)StandardGrade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 1
Grade No. 2
Grade No. 3
Grade No. 4
Grade No. 5
Grade No. 6
Grade No. 7
Grade No. 9 63.964 - 63.963 (2.5183 - 2.5182)
63.963 - 63.962 (2.5182 - 2.5182)
63.962 - 63.961 (2.5182 - 2.5181)
63.961 - 63.960 (2.5181 - 2.5181)
63.960 - 63.959 (2.5181 - 2.5181)
63.959 - 63.958 (2.5181 - 2.5180)
63.958 - 63.957 (2.5180 - 2.5180)
63.957 - 63.956 (2.5180 - 2.5179)
63.956 - 63.955 (2.5179 - 2.5179)
63.955 - 63.954 (2.5179 - 2.5179)
63.954 - 63.953 (2.5179 - 2.5178)
63.953 - 63.952 (2.5178 - 2.5178)
63.952 - 63.951 (2.5178 - 2.5178)
63.951 - 63.950 (2.5178 - 2.5177)
63.950 - 63.949 (2.5177 - 2.5177)
63.949 - 63.948 (2.5177 - 2.5176)
63.948 - 63.947 (2.5176 - 2.5176)
63.947 - 63.946 (2.5176 - 2.5176)
63.946 - 63.945 (2.5176 - 2.5175)
63.945 - 63.944 (2.5175 - 2.5175)
63.944 - 63.943 (2.5175 - 2.5174)
63.943 - 63.942 (2.5174 - 2.5174)
63.942 - 63.941 (2.5174 - 2.5174)
63.941 - 63.940 (2.5174 - 2.5173)
Main journal diameter. “Dm” grade
(No. 2, 3 and 4 journal) StandardGrade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 1
Grade No. 2 63.963 - 63.964 (2.5182 - 2.5183)
63.962 - 63.963 (2.5182 - 2.5182)
63.961 - 63.962 (2.5181 - 2.5182)
63.960 - 63.961 (2.5181 - 2.5181)
63.959 - 63.960 (2.5181 - 2.5181)
63.958 - 63.959 (2.5180 - 2.5181)
63.957 - 63.958 (2.5180 - 2.5180)
63.956 - 63.957 (2.5179 - 2.5180)
63.955 - 63.956 (2.5179 - 2.5179)
63.954 - 63.955 (2.5179 - 2.5179)
63.953 - 63.954 (2.5178 - 2.5179)
63.952 - 63.953 (2.5178 - 2.5178)
63.951 - 63.952 (2.5178 - 2.5178)
63.950 - 63.951 (2.5177 - 2.5178)
63.949 - 63.950 (2.5177 - 2.5177)
63.948 - 63.949 (2.5176 - 2.5177)
63.947 - 63.948 (2.5176 - 2.5176)
63.946 - 63.947 (2.5176 - 2.5176)
63.945 - 63.946 (2.5175 - 2.5176)
63.944 - 63.945 (2.5175 - 2.5175)
63.943 - 63.944 (2.5174 - 2.5175)
63.942 - 63.943 (2.5174 - 2.5174)
63.941 - 63.942 (2.5174 - 2.5174)
63.940 - 63.941 (2.5173 - 2.5174)
Pin journal diameter. “Dp” grade Standard Grade No. 0
Grade No. 1
Grade No. 253.968 - 53.974 (2.1247 - 2.1250)
53.962 - 53.968 (2.1245 - 2.1247)
53.956 - 53.962 (2.1243 - 2.1245)
SEM645
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*: Total indicator reading
Main BearingINFOID:0000000006289596
MAIN BEARING
UNDERSIZE
Unit: mm (in)
MAIN BEARING OIL CLEARANCE
Center distance “r”
45.96 - 46.04 (1.8095 - 1.8126)
Ta p e r Limit 0.0025 (0.0001)
Out-of-round 0.0025 (0.0001)
Crankshaft runout [TIR*] Standard Less than 0.05 (0.002)
Limit 0.10 (0.0039)
Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102)
Limit 0.30 (0.012)
Grade number Thickness mm (in) Width mm (in) Identification color Remarks
0 2.483 - 2.486 (0.0978 - 0.0979)
19.9 - 20.1
(0.783 - 0.791) Black
Grade is the same
for upper and lower
bearings.
1 2.486 - 2.489 (0.0979 - 0.0980) Brown
2 2.489 - 2.492 (0.0980 - 0.0981) Green
3 2.492 - 2.495 (0.0981 - 0.0982) Yellow
4 2.495 - 2.498 (0.0982 - 0.0983) Blue
5 2.498 - 2.501 (0.0983 - 0.0985) Pink
6 2.501 - 2.504 (0.0985 - 0.0986) Purple
7 2.504 - 2.507 (0.0986 - 0.0987) White
8 2.507 - 2.510 (0.0987 - 0.0988) Red
01 UPR 2.483 - 2.486 (0.0978 - 0.0979) Black
Grade and color are
different for upper
and lower bearings.
LWR 2.486 - 2.489 (0.0979 - 0.0980) Brown
12 UPR 2.486 - 2.489 (0.0979 - 0.0980) Brown
LWR 2.489 - 2.492 (0.0980 - 0.0981) Green
23 UPR 2.489 - 2.492 (0.0980 - 0.0981) Green
LWR 2.492 - 2.495 (0.0981 - 0.0982) Yellow
34 UPR 2.492 - 2.495 (0.0981 - 0.0982) Yellow
LWR 2.495 - 2.498 (0.0982 - 0.0983) Blue
45 UPR 2.495 - 2.498 (0.0982 - 0.0983) Blue
LWR 2.498 - 2.501 (0.0983 - 0.0985) Pink
56 UPR 2.498 - 2.501 (0.0983 - 0.0985) Pink
LWR 2.501 - 2.504 (0.0985 - 0.0986) Purple
67 UPR 2.501 - 2.504 (0.0985 - 0.0986) Purple
LWR 2.504 - 2.507 (0.0986 - 0.0987) White
78 UPR 2.504 - 2.507 (0.0986 - 0.0987) White
LWR 2.507 - 2.510 (0.0987 - 0.0988) Red
Items Thickness Main journal diameter
0.25 (0.0098) 2.618 - 2.626 (0.1031 - 0.1034) Grind so that bearing clearance is the specified value.
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SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
*: Actual clearance
Connecting Rod BearingINFOID:0000000006289597
CONNECTING ROD BEARING
UNDERSIZE
Unit: mm (in)
CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in)
*: Actual clearanceItems Standard Limit
Main bearing oil clearance No.1 and 5 0.001 - 0.011 (0.00004 - 0.00043)*
0.065 (0.0026)
No.2, 3 and 4 0.007 - 0.017 (0.0003 - 0.0007)*
Grade number Thickness mm (in) Width mm (in) Identification color (mark)
1 1.500 - 1.503 (0.0591 - 0.0592)
18.1 - 18.3
(0.713 - 0.720) Black
2 1.503 - 1.506 (0.0592 - 0.0593) Brown
3 1.506 - 1.509 (0.0593 - 0.0594) Green
4 1.509 - 1.512 (0.0594 - 0.0595) Yellow
Items Thickness Pin journal diameter
0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644) Grind so that bearing clearance is the specified value.
Items Standard Limit
Connecting rod bearing oil clearance 0.020 - 0.039 (0.0008 - 0.0015)* 0.070 (0.0028)
Revision: 2010 May2011 QX56