Cylinder Block Assembly: Specifications
Cylinder BlockThe cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).
Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.
Cylinder bore diameter
Grade 1 90.200 - 90.213 mm (3.5512 - 3.5517 inch)
Grade 2 90.213 - 90.226 mm (3.5517 - 3.5522 inch)
Grade 3 90.226 - 90.239 mm (3.5522 - 3.5527 inch)
Maximum taper 0.006 mm (0.0002 inch)
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)
Piston-to-cylinder bore clearance 0.012 - 0.0026 mm (0.0005 - 0.001 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
Diameter
Coded red 1 90.177 - 90.197 mm (3.550 - 3.551 inch)
Coded blue 2 90.190 - 90.210 mm (3.5507 - 3.5515 inch)
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)
Oil ring (steel rail) 0.05 - 0.66 mm (0.006 - 0.026 inch)
Groove width
Compression (top) 1.520 - 1.550 mm (0.060 - 0.610 inch)
Compression (bottom) 1.520 - 1.530 mm (0.060 - 0.0602 inch)
Oil ring 6.996 - 7.224 mm (0.275 - 0.2844 inch)
Width
Compression 1.49 - 1.47 mm (0.0587 - 0.0579 inch)
Oil ring rail (2) 0.473 - 0.447 mm (0.0186 - 0.0176 inch), 0.483 mm (0.0190 inch) maximum at ID
Oil ring expander 2.038 - 1.960 mm (0.080 - 0.077 inch)
Ring-to-groove clearance
Compression 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
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)
Pin diameter 22.0 mm (0.866 inch)
Pin length 61.8 mm (2.433 inch)
Pin-to-piston fit 0.005 - 0.010 mm (0.0002 - 0.0004 inch)
Connecting Rod
Rod-to-pin clearance 0.015 - 0.040 mm (0.0006 - 0.0016 inch)
Pin bore diameter 21.959 - 21.979 mm (0.864 - 0.865 inch)
Rod length (center-to-center) 150.7 mm (5.93 inch)
Maximum allowed bend 0.038 mm (0.0015 inch) per 25 mm (0.984 inch)
Maximum allowed twist a 0.050 mm (0.0019 inch) per 25 mm (0.984 inch)
Rod bearing bore diameter 56.756 - 56.876 mm (2.234 - 2.24 inch)
Rod bearing-to-crankshaft clearance 0.027 - 0.069 mm (0.001 - 0.0027 inch)
Rod side clearance (assembled to crank)
Standard 0.015 - 0.45 mm (0.0006 - 0.0177 inch)
Service limit 0.05 mm (0.02 inch) maximum
a 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.
Main Bearing Size Codes
Remove and discard the main cap bolts.
Vertical main bearing cap bolts
First pass 40 Nm (30 ft. lbs.)
Final pass tighten 90°
Remove and discard the cross-mounted main cap bolts.
Jack screws
First pass 5 Nm (44 inch lbs.)
Final pass 10 Nm (89 inch lbs.)
Remove and discard the cross-mounted main cap bolts.
Side bolts 21 Nm (15 ft. lbs.)
Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
First pass 90 Nm (66 ft. lbs.)
Second pass loosen one full turn
Third pass 50 Nm (37 ft. lbs.)
Final pass tighten 90° without exceeding 200 Nm (148 ft. lbs.)