System Specifications
Cylinder BlockHead Gasket Surface
Flatness 0.08 mm (0.003 inch) in 152.0 mm (6.00 inch)
Finish (RMS) 1.0-3.3 Micrometers
Cylinder Bore
Diameter 89.00 mm (3.504 inch)
Surface Finish (RMS) 0.45-0.96 micrometers
Out-of-Round
Limit 0.025 mm (0.001 inch)
Service Limit 0.050 mm (0.002 inch)
Taper Service Limit 0.050 mm (0.002 inch)
Main Bearing Bore 68.905 mm (2.713 inch)
Diameter 68.885 mm (2.712 inch)
Crankshaft
Main Bearing Journal
Diameter 63.983-64.003 mm (2.5190-2.5198 inch)
Out-of-Round Limit 0.008 mm (0.0003 inch)
Taper Limit 0.06 mm (0.0006 inch)
Total 0.013 mm (0.0003 inch) per 25 mm (1 inch)
Journal Runout Limit(a) 0.05 mm (0.002 inch)
Journal Runout Limit(b) 0.05 mm (0.002 inch)
Surface Finish (RMS) 0.25 Micrometers (10.0 Micro inch)
Thrust Bearing Journal Length 25.775-25.825 mm (1.0148-1.067 inch)
Connecting Rod Journal
Diameter 53.983-54.003 mm (2.1253-2.1261 inch)
Out-of-Round
Limit 0.006 mm (0.0003 inch)
Max. 0.0150 mm (0.0006 inch) Total
Taper Limit 0.008 mm per 25 mm (0.0003 inch per inch)
Surface Limit (RMS) 0.25 Micrometers (10.0 Micro inch)
Main Bearing Thrust Face
Surface Finish (RMS)
Front 0.4 Micrometers (0.157 Micro inch)
Rear 0.4 Micrometers (0.157 Micro inch)
Runout Limit 0.025 mm (0.001 inch)
Crankshaft End Play 0.10-0.20 mm (0.004-0.008 inch)
(a) Runout of journals II and III to journals I and IV.
(b) Runout of adjacent journals to each other.
Connecting Rod Bearings
Clearance to Crankshaft
Desired 0.025-0.035 mm (0.001-0.0014 inch)
Allowable 0.020-0.066 mm (0.00086-0.0027 inch)
Bearing Wall Thickness (Std.) 1.557-1.570 mm (0.0612-0.0618 inch)
Main Bearings
Clearance to Crankshaft
Desired 0.25-0.035 mm (0.001-0.0014 inch)
Allowable 0.020-0.066 mm (0.0005-0.0023 inch)
Bearing Wall Thickness
(Std.) 1st and 2nd 2.444-2.481 mm (0.0962-0.0967 inch)
3rd and Rear 2.427-2.491 mm (0.0955-0.0980 inch)
Crankshaft Main Bearing Cap Bolts 80 Nm (59 ft. lbs).
Connecting Rod
Piston Pin Bore Diameter 23.105-23.145 mm (0.9096-0.9112 inch)
Crankshaft Bearing Bore Diameter 5.15-5.17 mm (2.250-2.251 inch)
Length (Center-to-Center) 140.46-140.54 mm (5.530-5.533 inch)
Alignment (Bore-to-Bore Max Diff.)
Twist 0.075 per 25 mm (0.003 per inch)
Bend 0.04 per 25 mm (0.0016 per inch)
Side Clearance (Assembled to Crank)
Standard 0.15-0.35 mm (0.006-0.014 inch)
Service Limit 0.36 mm Max. (0.014 inch Max.)
Piston
Diameter
Coded Red 88.962-88.978 mm (3.5024-3.5031 inch)
Coded Blue 88.988-89.004 mm (3.5035-3.5041 inch)
Coded Yellow 89.014-89.030 mm (3.5045-3.5051 inch)
Piston-to-Bore Clearance 0.030-0.056 mm (0.0012-0.0022 inch)
Service Limit 0.081 mm Max.
Ring Groove Width
Compression (Top) 1.530-1.555 mm (0.0602-0.0612 inch)
Compression (Bottom) 1.530-1.555 mm (0.0602-0.0612 inch)
Oil 4.030-4.055 mm (0.1587-0.1596 inch)
Piston Pin
Length 76.5-77.2 mm (3.012-3.039 inch)
Diameter 23.162-23.175 mm (0.9119-0.9124 inch)
Clearance to Piston 0.005-0.012 mm (0.0002-0.0005 inch)
Clearance to Rod Press Kit 4 KiloNewtons (900 Lbs.)
Service Piston Selection(c)
Piston Bore Diameter & Service Piston Grade Required
89.009-89.035 mm (3.5043-3.5053 inch) Red
89.035-89.060 mm (3.5053-3.5063 inch) Blue
89.060-89.086 mm (3.5063-3.5073 inch) Yellow
(c) When replacing pistons, measure the cylinder bore and install the indicated service piston.
Piston Rings
Ring Width
Compression
Top 1.460-1.490 mm (0.0575-0.0587 inch)
Bottom 1.460-1.490 mm (0.0575-0.0587 inch)
Oil Ring Side Seal - Snug Fit
Service Limit Side Clearance 0.15 mm Max. (0.006 inch Max.)
Ring Gap (In Gauge)
Compression
Top 0.25-0.50 mm (0.01-0.02 inch)
Bottom 0.25-0.50 mm (0.01-0.02 inch)
Oil Ring (Steel Rail) 0.25-1.25 mm (0.010-0.049 inch)
Side Clearance
1st Ring 0.040-0.095 mm (0.0016-0.0037 inch)
2nd Ring 0.040-0.095 mm (0.0016-0.0037 inch)
Crankshaft damper bolt 145 Nm (107 ft. lbs).