System Specifications
Cylinder BlockCylinder bore
Diameter 96.813 mm (3.81 inch)
Maximum taper 0.050 mm (0.002 inch)
Maximum out-of-round
Limit 0.025 mm (0.001 inch)
Service limit 0.050 mm (0.002 inch)
Main bearing bore inside diameter 68.905-68.885 mm (2.713-2.712 inch)
Camshaft bearing bore inside diameter
No. 1 55.689-55.664 mm (2.192-2.191 inch)
No. 2 and No. 3 55.308-55.283 mm (2.177-2.176 inch)
No. 4 55.684-55.664 mm (2.192-2.191 inch)
Head gasket surface
Flatness 0.08 mm (0.003 inch) in 152.0 mm (6.00 inch)
Finish (RMS) 2.0 @ 0.85.5 @ 2.5
Balance Shaft
Journal diameter 52.108-52.082 mm (2.0515-2.0505 inch)
Bore inside diameter 55.689-55.664 mm (2.192-2.191 inch)
Maximum runout 0.025 mm (0.001 inch)
End play 0.075-0.200 mm (0.003-0.008 inch)
Crankshaft
Main bearing journal
Diameter - 1, 2, 3 63.983-64.003 mm (2.5190-2.5198 inch)
Maximum taper 0.008 mm (0.0003 inch) per 25 mm (1 inch)
Maximum out-of-round 0.008 mm (0.0003 inch) max in 45 degrees, 0.015 mm (0.0006 inch) total
Clearance-to-cylinder block
Desired 0.025-0.035 mm (0.001-0.0014 inch)
Allowable 0.013-0.058 mm (0.0005-0.0023 inch)
Maximum end play 0.10-0.20 mm (0.004-0.008 inch)
Thrust bearing journal
Diameter 58.682-58.702 mm (2.3103-2.3111 inch)
Maximum out-of-round 0.008 mm (0.0003 inch) max in 45 degrees, 0.015 mm (0.0006 inch) total
Maximum taper
Limit 0.008 mm per 25 mm (0.0003 in per inch)
Service limit 0.3 microns (11.8 micro inch)
Length 29.725-29.775 mm (1.703-1.722 inch)
Piston
Diameter
Coded red 96.795-96.782 mm (3.8108-3.8103 inch)
Coded blue 96.808-96.795 mm (3.8113-3.8108 inch)
Coded yellow 96.821-96.808 mm (3.8119-3.8113 inch)
Clearance-to-cylinder bore (uncoated clearance) 0.018-0.044 mm (0.0007-0.0017 inch)
Ring end gap
Compression
(top, in gauge) 0.17-0.33 mm (0.0067-0.0130 inch)
(bottom, in gauge) 0.3-0.55 mm (0.0118-0.0217 inch)
Oil ring (steel rail, in gauge) 0.15-0.65 mm (0.006-0.026 inch)
Ring groove width
Compression (top and bottom) 1.54-1.52 mm (0.0606-0.0598 inch)
Oil 3.05-3.03 mm (0.1201-0.1193 inch)
Ring width
Compression (top and bottom) 1.460-1.490 mm (0.0575-0.0587 inch)
Oil ring Side seal, snug fit
Ring-to-groove clearance
1st ring 0.030-0.080 mm (0.0012-0.0032 inch)
2nd ring 0.030-0.080 mm (0.0012-0.0032 inch)
Pin bore diameter 23.014-23.018 mm (0.9061-0.9062 inch)
Piston pin
Diameter 23.000-23.003 mm (0.9055-0.9056 inch)
Length 63.55-63.05 mm (2.5020-2.4823 inch)
Fit-to-piston 0.011-0.018 mm (0.0004-0.0007 inch)
Clearance-to-connecting rod Press fit 8 kilonewtons (1,800 lb)
Connecting Rod
Pin bore diameter 22.94-22.98 mm (0.9032-0.9047 inch)
Length (center-to-center) 154.66-154.74 mm (6.0890-6.0921 inch)
Maximum allowable bend 0.04 per 25 mm (0.0016 in per inch)
Maximum allowable twist 0.059 per 25 mm (0.002 in per inch)
Bearing bore diameter 61.635-61.655 mm (2.4266-2.4274 inch)
Side clearance (assembled to crank)
Standard 0.11-0.49 mm (0.0043-0.0193 inch)
Service limit 0.36 mm (0.014 inch) max.
Connecting Rod Bearing
Clearance-to-crankshaft
Desired 0.025-0.035 mm (0.001-0.0014 inch)
Allowable 0.022-0.069 mm (0.0009-0.0027 inch)
Main Bearing Cap Bolts
First pass 55 Nm (41 lb-ft).
Final pass Rotate an additional 90°
Connecting Rod Cap Bolts
First pass 25 Nm (18 lb-ft).
Second pass 45 Nm (33 lb-ft).
Final pass Tighten an additional 105°
Crankshaft Pulley Bolt 160 Nm (118 lb-ft).