Engine Block
ENGINE BLOCK STANDARDS AND SERVICE LIMITS SPECIFICATIONS
| 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 | A or I | 86.010-86.020 mm (3.3862-3.3866 in.) | 86.070 mm (3.3886 in.) | |
| B or II | 86.000-86.010 mm (3.3858-3.3862 in.) | 86.070 mm (3.3886 in.) | ||
| Bore taper | - | 0.05 mm (0.002 in.) | ||
| Reboring limit | - | 0.25 mm (0.01 in.) | ||
| Piston | Skirt O.D. at 11 mm (0.4 in.) from bottom of skirt | No letter or A | 85.980-85.990 mm (3.3850-3.3854 in.) | 85.930 mm (3.3831 in.) |
| Letter B | 85.970-85.980 mm (3.3846-3.3850 in.) | 85.920 mm (3.3827 in.) | ||
| Clearance in cylinder | 0.020-0.040 mm (0.0008-0.0016 in.) | 0.05 mm (0.002 in.) | ||
| Ring groove width | Top (K20A3 engine) |
1.220-1.230 mm (0.0481-0.0484 in.) | 1.25 mm (0.049 in.) | |
| Top [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
1.235-1.245 mm (0.0486-0.0490 in.) | 1.265 mm (0.0498 in.) | ||
| Second (K20A3 engine) |
1.220-1.230 mm (0.0481-0.0484 in.) | 1.25 mm (0.049 in.) | ||
| Second [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
1.230-1.240 mm (0.0484-0.0488 in.) | 1.260 mm (0.0496 in.) | ||
| Oil | 2.005-2.025 mm (0.0789-0.0797 in.) | 2.05 mm (0.081 in.) | ||
| Piston ring | Ring-to-groove clearance | Top (K20A3 engine) |
0.035-0.060 mm (0.0014-0.0024 in.) | 0.13 mm (0.005 in.) |
| Top [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
0.040-0.065 mm (0.0016-0.0026 in.) | 0.13 mm (0.005 in.) | ||
| Second (K20A3 engine) |
0.030-0.055 mm (0.0012-0.0022 in.) | 0.13 mm (0.005 in.) | ||
| Second [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
0.045-0.070 mm (0.0018-0.0028 in.) | 0.13 mm (0.005 in.) | ||
| Ring end gap | Top | 0.20-0.35 mm (0.008-0.014 in.) | 0.60 mm (0.024 in.) | |
| Second (K20A3 engine) |
0.40-0.55 mm (0.016-0.022 in.) | 0.70 mm (0.028 in.) | ||
| Second [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
0.50-0.65 mm (0.020-0.026 in.) | 0.75 mm (0.030 in.) | ||
| Oil (K20A3 engine) |
0.25-0.65 mm (0.010-0.026 in.) | 0.75 mm (0.030 in.) | ||
| Oil [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
0.20-0.70 mm (0.008-0.028 in.) | 0.80 mm (0.031 in.) | ||
| Piston pin | O.D. | 21.961-21.965 mm (0.8646-0.8648 in.) | 21.953 mm (0.8643 in.) | |
| Pin-to-piston clearance | -0.005 to +0.002 mm (-0.00020 to +0.00008 in.) | 0.005 mm (0.0002 in.) | ||
| Connecting rod | Pin-to-rod clearance | 0.005-0.015 mm (0.0002-0.0006 in.) | 0.02 mm (0.0008 in.) | |
| Small-end bore diameter | 21.970-21.976 mm (0.8650-0.8652 in.) | - | ||
| Large-end bore diameter | K20A3 engine | 48.0 mm (1.89 in.) | - | |
| K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines |
51.0 mm (2.01 in.) | - | ||
| End play | 0.15-0.30 mm (0.006-0.012 in.) | 0.40 mm (0.016 in.) | ||
| Crankshaft | Main journal diameter | No. 1 journal No. 2 journal No. 4 journal No. 5 journal (K20A3 engine) |
54.984-55.008 mm (2.1648-2.1657 in.) | - |
| No. 1 journal No. 2 journal No. 4 journal No. 5 journal [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
54.980-55.004 mm (2.1646-2.1655 in.) | - | ||
| No. 3 journal (K20A3 engine) |
54.976-55.000 mm (2.1644-2.1654 in.) | - | ||
| No. 3 journal [K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines] |
54.974-54.996 mm (2.1644-2.1652 in.) | - | ||
| Rod journal diameter | K20A3 engine | 44.976-45.000 mm (1.7707-1.7717 in.) | - | |
| K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines |
47.976-48.000 mm (1.8888-1.8898 in.) | - | ||
| Rod/main journal taper | 0.005 mm (0.0002 in.) | 0.010 mm (0.0004 in.) | ||
| Rod/main journal out-of-round | 0.005 mm (0.0002 in.) | 0.010 mm (0.0004 in.) | ||
| End play | 0.10-0.35 mm (0.004-0.014 in.) | 0.45 mm (0.018 in.) | ||
| Runout | K20A3 engine | 0.03 mm (0.0012 in.) max. | 0.04 mm (0.0016 in.) | |
| K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines |
0.02 mm (0.0008 in.) max. | 0.03 mm (0.0012 in.) | ||
| Crankshaft bearing | Main bearing-to-journal oil clearance | No. 1 journal No. 2 journal No. 4 journal No. 5 journal |
0.017-0.041 mm (0.0007-0.0016 in.) | 0.050 mm (0.0020 in.) |
| No. 3 journal | 0.025-0.049 mm (0.0010-0.0019 in.) | 0.055 mm (0.0022 in.) | ||
| Rod bearing clearance | K20A3 engine | 0.020-0.050 mm (0.0008-0.0020 in.) | 0.060 mm (0.0024 in.) | |
| K20A2 (2002-2004 models), K20Z1 (2005-2006 models) engines |
0.033-0.061 mm (0.0013-0.0024 in.) | 0.072 mm (0.0028 in.) |