System Specifications
Cylinder BlockCylinder bore diameter-grade 1 90.200-90.213 mm (3.5512-3.5517 inch)
Cylinder bore diameter-grade 2 90.213-90.226 mm (3.5517-3.5522 inch)
Cylinder bore diameter-grade 3 90.226-90.239 mm (3.5522-3.5527 inch)
Cylinder bore maximum taper 0.006 mm (0.0002 inch)
Cylinder bore maximum out-of-round 0.020 mm (0.0008 inch)
Main bearing bore inside diameter 72.401-72.422 mm (2.850-2.851 inch)
Crankshaft
Main bearing journal diameter 63.0 mm (2.4803 inch)
Main bearing journal maximum taper 0.020 mm (0.0007 inch)
Main bearing journal maximum out-of-round 0.05 mm (0.002 inch)
Main bearing journal-to-cylinder block clearance 0.027-0.065 mm (0.0011 -0.0026 inch)
Connecting rod journal diameter 52.988-53.003 mm (2.0861-2.0867 inch)
Connecting rod journal maximum taper 0.015 mm (0.0006 inch)
Connecting rod journal maximum out-of-round 0.05 mm (0.0020 inch)
Crankshaft maximum end play 0.130-0.301 mm (0.0051-0.012 inch)
Piston and Connecting Rod
Piston diameter-coded red 1 90.177-90.197 mm (3.550-3.551 inch)
Piston diameter-coded blue 2 90.190-90.210 mm (3.5507-3.5515 inch)
Piston diameter-coded yellow 3 90.203-90.223 mm (3.513-3.5521 inch)
Piston-to-cylinder bore clearance 0.012-0.0026 mm (0.0005-0.001 inch)
Piston ring end gap-compression (top and bottom) 0.23-0.49 mm (0.010-0.020 inch)
Piston ring end gap-oil ring (steel rail) 0.05-0.66 mm (0.006-0.026 inch)
Piston ring groove width * compression (top) 1.520-1.550 mm (0.060-0.610 inch)
Piston ring groove width * compression (bottom) 1.520-1.530 mm (0.060-0.0602 inch)
Piston ring groove width * oil ring 6.996-7.224 mm (0.275-0.2844 inch)
Piston ring width- compression 1.49-1.47 mm (0.0587-0.0579 inch)
Piston ring width-oil ring rail (2) 0.473-0.447 mm (0.0186-0.0176 inch), 0.483 mm (0.0190 inch) max. at ID
Piston ring width-oil ring expander 2.038-1.960 mm (0.080-0.077 inch)
Piston ring-to-groove clearance-compression 0.030-0.070 mm (0.0012-0.0028 inch)
Piston ring-to-groove clearance-oil ring assembly 0.046-0.196 mm (0.0018-0.0077 inch)
Piston pin bore diameter 22.0015-22.004 mm (0.866-0.8663 inch)
Piston pin diameter 22.0 mm (0.866 inch)
Piston pin length 61.8 mm (2.433 inch)
Piston pin-to-piston fit 0.005-0.010 mm (0.0002-0.0004 inch)
Connecting rod-to-pin clearance 0.015-0.040 mm (0.0006-0.0016 inch)
Connecting rod pin bore diameter 21.959-21.979 mm (0.864-0.865 inch)
Connecting rod length (center-to-center) 150.7 mm (5.93 inch)
Connecting rod maximum allowed bend 0.038 mm (0.0015 inch) per 25 mm (0.984 inch)
Connecting rod maximum allowed twists 0.050 mm (0.0019 inch) per mm (0.984 inch)
Connecting rod bearing bore diameter 56.756-56.876 mm (2.234-2.24 inch)
Connecting rod bearing-to-crankshaft clearance 0.027-0.069 mm (0.001-0.0027 inch)
Connecting rod side clearance (assembled to crank)-standard 0.015-0.45 mm (0.0006-0.0177 inch)
Connecting rod side clearance (assembled to crank)-service limit 0.05 mm (0.02 inch) max.
.a Time required for the plunger to leak down 1.6 mm of travel with 222 N force and leak-down fluid in the lash adjuster
.b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline.
Crankshaft Main Bearing Bolts
Install the vertical main bearing cap fasteners and tighten in two stages, in the sequence shown.
Stage 1: Tighten to 40 Nm (30 ft. lbs.).
Stage 2: Tighten an additional 90 degrees.
Tighten the jack screws against the cylinder block in two stages, in the sequence shown.
Stage 1: Tighten to 5 Nm (44 inch lbs.).
Stage 2: Tighten to 10 Nm (89 inch lbs.).
Side bolts 21 Nm (15 ft.lbs.).
Connecting Rod Cap Bolts
Stage 1: Tighten to 43 Nm (32 ft. lbs.).
Stage 2: Tighten an additional 105 degrees.
Crankshaft Pulley
Stage 1: Tighten to 90 Nm (66 ft. lbs.).
Stage 2: Loosen 360 degrees.
Stage 3: Tighten to 50 Nm (37 ft. lbs.).
Stage 4: Tighten an additional 90 degrees.