P-1226 2.

2 Litre Engine Bumping Clearance Calculation

I.) Bumping Clearance at Intake TDC Calculation (Minimum, Nominal, Maximum )
a.) Block Height ( Top Surface to Crank Bore Centre Line )
244.350 244.400 244.450
b.) Compressed gasket thickness, mm
1.3 1.2 1.1
c.) Main Bearing Housing
Clearance at cold condition
Housing Pin Bearing Minimum Nominal Maximum
66.000 66.019 62.000 61.981 1.970 1.980 0.040 0.073 0.098
d.) Crank Shaft Stroke
47.950 48.000 48.050
e.) Connecting Rod Big End
Clearance at cold condition
Housing Pin Bearing Minimum Nominal Maximum
55.000 55.019 51.000 50.981 1.992 1.982 0.016 0.045 0.074
f.) Connecting Rod centre Distance
148.980 149.000 149.020
g.) Connecting Rod Small End
Small End to Piston Pin Clearance to Con. Rod
Con. Rod Bush Pin Piston Minimum Nominal Maximum
31.010 31.020 30.990 30.996 31.003 31.009 0.014 0.022 0.030
h.) Piston Pin to Piston Clearance to Piston
Minimum Nominal Maximum
0.007 0.013 0.019
i.) Piston Compression Height
47.970 48.000 48.030
j.) Clearances in Bearings / Connections
Elements Minimum Nominal Maximum
Clearance in Main Bearing 0.040 0.073 0.098
Clearance in Con Rod bearing 0.016 0.045 0.074
Clearance in Con. Rod Small End / Piston pin 0.014 0.022 0.030
Clearance in Piston Pin / Piston 0.007 0.013 0.019
Total Diametrical Clearances 0.077 0.153 0.221
Total Radial Clearances 0.039 0.077 0.111
Bumping Clearance calculations
A.) Bumping Clearance Calculation w/o brg clearance Nominal Maximum Minimum
1.1.) Block Height 244.400 244.450 244.350 mm
1.3.) Piston Projection Corresponding to Max,Nom,Min Bumping
Clearances 0.600 0.450 0.750
1.4.) Recommended Compressed Gasket Thickness 1.300 1.200 1.400 mm
Total (1) 245.700 245.650 245.750 mm
2.1.) Crank Stroke 48.000 47.950 48.050 mm
2.2.) Connecting Rod Centre Distance 149.000 148.980 149.020 mm
2.3.) Compression Height 48.000 47.970 48.030 mm
 Total (2) 245.000 244.900 245.100 mm
Calculated Bumping Clearance, mm ( 1-2 ) 0.700 0.750 0.650 mm
B.) Minimum, Nominal and maximum bumping clearance Considering Bearing Clearances
Nom. Max. Min.

B.1.) Bumping Clearances at Intake TDC, all clearances

0.624 0.712 0.540 mm
up

B.2.) Bumping Clearances Meas. By Lead Wire, all

0.777 0.861 0.689 mm
Clearances Down Corresponding to B.1 Clearance

C.) Bumping Clearance with Thermal Effects on Liner Dimensions and not on Clearances
C.1.) Resultant Expansion of components due to
0.406 mm
Calculated thermal effect, mm

C.2.) Bumping Clearance with Both Calculated Bearing

0.218 0.305 0.134 mm
Clearances up and Thermal Effect

C.3.) Bumping Clearance with Both Calculated Bearing

0.371 0.455 0.283 mm
Clearances down and Thermal Effect

D.) Bumping Clearance with Bearing Clearance, Thermal Expansion, Dynamic Expansion

D.1.) Mechanical Expansion due to Inertia Forces

0.1 mm
( assumed )

D.2.) Dynamic Clearance ( Clearance Up ) 0.118 0.205 0.034 mm

D.3.) Dynamic Clearance ( Clearance down ) 0.271 0.355 0.183 mm

 NEF.3800 TCI
I.) Bumping Clearance at Intake TDC Calculation (Minimum, Nominal, Maximum )
a.) Block Height ( Top Surface to Crank Bore Centre Line )
258.450 258.500 258.550
b.) Compressed gasket thickness, mm
1.3
c.) Main Bearing Housing
Clearance at cold condition
Housing Pin Bearing Minimum Nominal Maximum
64.000 64.019 59.000 58.981 2.470 2.480 0.040 0.073 0.098
d.) Crank Shaft Stroke
46.950 47.000 47.050
e.) Connecting Rod Big End
Clearance at cold condition
Housing Pin Bearing Minimum Nominal Maximum
57.000 57.019 53.000 52.981 1.992 1.982 0.016 0.045 0.074
f.) Connecting Rod centre Distance
157.980 158.000 158.020
g.) Connecting Rod Small End
Small End to Piston Pin Clearance to Con. Rod
Con. Rod Bush Pin Piston Minimum Nominal Maximum
31.010 31.020 30.990 30.996 31.003 31.009 0.014 0.022 0.030
h.) Piston Pin to Piston Clearance to Piston
Minimum Nominal Maximum
0.007 0.013 0.019
i.) Piston Compression Height
54.050 54.080 54.110
j.) Clearances in Bearings / Connections
Elements Minimum Nominal Maximum
Clearance in Main Bearing 0.040 0.073 0.098
Clearance in Con Rod bearing 0.016 0.045 0.074
Clearance in Con. Rod Small End / Piston pin 0.014 0.022 0.030
Clearance in Piston Pin / Piston 0.007 0.013 0.019
Total Diametrical Clearances 0.077 0.153 0.221
Total Radial Clearances 0.039 0.077 0.111
Bumping Clearance calculations a) Without bearing Clearances b) With Bearing Clearances
A.) Bumping Clearance Calculation w/o clearance Nominal Maximum Minimum
1.1 Block Height 258.500 258.550 258.450 mm
1.2 Compressed Gasket Thickness 1.300 1.300 1.300 mm
Total (1) 259.800 259.850 259.750 mm
2.1 Crank Stroke 47.000 46.950 47.050 mm
2.2 Connecting Rod Centre Distance 158.000 157.980 158.020 mm
2.3 Compression Height 54.080 54.050 54.110 mm
Total (2) 259.080 258.980 259.180 mm
Calculated Bumping Clearance, mm ( 1-2 ) 0.720 0.870 0.570 mm
B.) Minimum, Nominal and maximum bumping clearance Considering Bearing Clearances
Nom. Max. Min.

B.1.)Bumping Clearances at Intake TDC, all clearances

0.644 0.832 0.459 mm
up

B.2.)Bumping Clearances Meas. By Lead Wire, all

0.797 0.981 0.608 mm
Clearances Down Corresponding to B.1 Clearance

C.) Bumping Clearance with Thermal Effects on Liner Dimensions and not on Clearances
C.1.) Resultant Expansion of components due to
0.406 mm
Calculated thermal effect, mm

C.2.) Bumping Clearance with Both Calculated Bearing

0.238 0.426 0.053 mm
Clearances up and Thermal Effect

C.3.) Bumping Clearance with Both Calculated Bearing

0.391 0.575 0.202 mm
Clearances down and Thermal Effect

D.) Bumping Clearance with Bearing Clearance, Thermal Expansion, Dynamic Expansion

D.1.) Mechanical Expansion due to Inertia Forces

0.1 mm
( assumed )

D.2.) Dynamic Clearance ( Clearance Up ) 0.138 0.326 -0.047 mm

D.3.) Dynamic Clearance ( Clearance down ) 0.291 0.475 0.102 mm

 P-1226 2.2 Litre Engine Bumping Clearance Calculation
I.) Bumping Clearance at Intake TDC Calculation (Minimum, Nominal, Maximum )
a.) Block Height ( Top Surface to Crank Bore Centre Line )
226.300 226.350 226.400
b.) Compressed gasket thickness, mm
0.6 0.6 0.6
c.) Main Bearing Housing
Clearance at cold condition
Housing Pin Bearing Minimum Nominal Maximum
62.000 62.019 58.000 57.981 1.970 1.980 0.040 0.073 0.098
d.) Crank Shaft Stroke
41.950 42.000 42.050
e.) Connecting Rod Big End
Clearance at cold condition
Housing Pin Bearing Minimum Nominal Maximum
50.000 50.019 47.000 46.981 1.492 1.482 0.016 0.045 0.074
f.) Connecting Rod centre Distance
140.480 140.500 140.520
g.) Connecting Rod Small End
Small End to Piston Pin Clearance to Con. Rod
Con. Rod Bush Pin Piston Minimum Nominal Maximum
30.010 30.020 29.990 29.996 30.003 30.009 0.014 0.022 0.030
h.) Piston Pin to Piston Clearance to Piston
Minimum Nominal Maximum
0.007 0.013 0.019
i.) Piston Compression Height
43.720 43.750 43.780
j.) Clearances in Bearings / Connections
Elements Minimum Nominal Maximum
Clearance in Main Bearing 0.040 0.073 0.098
Clearance in Con Rod bearing 0.016 0.045 0.074
Clearance in Con. Rod Small End / Piston pin 0.014 0.022 0.030
Clearance in Piston Pin / Piston 0.007 0.013 0.019
Total Diametrical Clearances 0.077 0.153 0.221
Total Radial Clearances 0.039 0.077 0.111
Bumping Clearance calculations
A.) Bumping Clearance Calculation w/o brg clearance Nominal Maximum Minimum
1.1.) Block Height 226.350 226.400 226.300 mm
1.3.) Piston Projection Corresponding to Max,Nom,Min Bumping
Clearances -0.100 -0.250 0.050
1.4.) Recommended Compressed Gasket Thickness 0.600 0.540 0.660 mm
Total (1) 226.950 226.940 226.960 mm
2.1.) Crank Stroke 42.000 41.950 42.050 mm
2.2.) Connecting Rod Centre Distance 140.500 140.480 140.520 mm
2.3.) Compression Height 43.750 43.720 43.780 mm
 Total (2) 226.250 226.150 226.350 mm
Calculated Bumping Clearance, mm ( 1-2 ) 0.700 0.790 0.610 mm
B.) Minimum, Nominal and maximum bumping clearance Considering Bearing Clearances
Nom. Max. Min.

B.1.) Bumping Clearances at Intake TDC, all clearances

0.623 0.751 0.499 mm
up

B.2.) Bumping Clearances Meas. By Lead Wire, all

0.776 0.900 0.648 mm
Clearances Down Corresponding to B.1 Clearance

C.) Bumping Clearance with Thermal Effects on Liner Dimensions and not on Clearances
C.1.) Resultant Expansion of components due to
0.406 mm
Calculated thermal effect, mm

C.2.) Bumping Clearance with Both Calculated Bearing

0.217 0.345 0.093 mm
Clearances up and Thermal Effect

C.3.) Bumping Clearance with Both Calculated Bearing

0.370 0.494 0.242 mm
Clearances down and Thermal Effect

D.) Bumping Clearance with Bearing Clearance, Thermal Expansion, Dynamic Expansion

D.1.) Mechanical Expansion due to Inertia Forces

0.1 mm
( assumed )

D.2.) Dynamic Clearance ( Clearance Up ) 0.117 0.245 -0.007 mm

D.3.) Dynamic Clearance ( Clearance down ) 0.270 0.394 0.142 mm