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 - 90.210 mm
Grade 2 90.210 - 90.220 mm
Grade 3 90.220 - 90.230 mm
Piston
Diameter (Grade 2) at right angle-to-pin bore 90.180 ± 0.005 mm
Piston-to-bore clearance (-0.005) to +0.025 mm
Pin bore diameter (piston) 22.008-22.014 mm
Pin diameter 22.0010 - 22.0030 mm
Clearance (neg. or pos.) 0.0139 - 0.005 mm
Pin bore diameter (rod) 22.012 - 22.024 mm
Clearance 0.009 - 0.023 mm
Ring groove width
Top 1.503 - 1.505 mm
Intermediate 1.502 - 1.504 mm
Oil control 3.030 - 3.050 mm
Ring gap
Top 0.15 - 0.30 mm
Intermediate 0.25 - 0.50 mm
Oil control 0.15 - 0.65 mm
Crankshaft
Main bearing journal
Diameter 67.481 - 67.505 mm
Maximum out-of-round 0.0075 mm between cross sections
Maximum taper (straightness) 0.004 mm
Runout: FIM of center journals when located on front and rear journal 0.05 mm (3 places)
Clearance - crankshaft journal-to-main bearing clearance 0.048 - 0.024 mm
Connecting rod journal
Diameter 53.003 - 52.983 mm
Maximum out-of-round 0.0075 mm between cross sections
Maximum taper 0.004 mm
Crankshaft end play 0.075 - 0.377 mm
Connecting Rod
Big end journal inside diameter with assembled liners 53.049 - 53.027 mm
Rod bearing-to-journal clearance 0.064 - 0.026 mm
Pin bore diameter (rod) 22.024 - 22.012 mm
Main Bearing Size Codes
Remove and discard the main cap bolts.
Main bearing cap fasteners 1-12
First pass 40 Nm (30 ft. lbs.)
Final pass tighten 90°
Remove and discard the cross-mounted main cap bolts.
Main bearing cap fasteners 13-24
First pass 30 Nm (22 ft. lbs.)
Final pass tighten 90°
Crankshaft Pulley Bolt
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.)