System Specifications
Cylinder BlockCylinder 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 (0.00023 inch)
Maximum out-of-round 0.020 mm (0.00079 inch)
Diameter-surface finish (RMS) 0.2-0.6 microns
Main bearing bore inside diameter 72.402-72.422 mm (2.850-2.851 inch)
Crankshaft
Main bearing journal
Diameter 67.483-67.503 mm (2.65 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round 0.06 mm (0.002 inch)
Clearance-to-cylinder block 0.027-0.065 mm (0.0011-0.0026 inch)
Connecting rod journal
Diameter 52.983-53.003 mm (2.0859-2.0867 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round 0.006 mm (0.0002 inch)
Maximum end play 0.130-0.301 mm (0.0051-0.012 inch)
Vertical Main Bearing Cap Fasteners
Discard the fasteners.
First pass 40 Nm (30 lb-ft).
Final pass Tighten an additional 90°
Jack Screws
Discard the screws.
First pass 5 Nm (44 lb-in).
Final pass 10 Nm (89 lb-in).
Side Bolts 21 Nm (15 lb-ft).
Discard the bolts.
Crankshaft Main Bearing Codes
Connecting Rod
Clearance-to-pin 0.015-0.040 mm (0.0006-0.0016 inch)
Pin bore diameter 21.959-21.979 mm (0.864-0.865 inch)
Length (center-to-center) 150.7 mm (5.93 inch)
Maximum allowed bend 0.038 mm per 25 mm (0.0015-0.984 inch)
Maximum allowed twist (a) 0.050 mm per 25 mm (0.0015-0.984 inch)
Bearing bore diameter 56.756-56.876 mm (2.234-2.24 inch)
Bearing-to-crankshaft clearance 0.027-0.069 mm (0.001-0.0027 inch)
Side clearance (assembled to crank)
Standard 0.015-0.45 mm (0.0006-0.0177 inch)
Service limit 0.05 mm (0.002 inch) max.
(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.
Connecting Rod Cap Bolts
Discard the bolts.
First pass 43 Nm (32 lb-ft).
Final pass Tighten an additional 105°
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)
Clearance-to-cylinder bore 0.012-0.0026 mm (0.0005-0.0001 inch)
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)
Ring groove width
Compression (top) 1.520-1.550 mm (0.002-0.610 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)
Ring 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) max. 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)
Pin
Bore diameter 22.0015-22.004 mm (0.866-0.8663 inch)
Pin diameter 22.0 mm (0.866 inch)
Length 61.8 mm (2.433 inch)
Fit-to-piston 0.005-0.010 mm (0.0002-0.0004 inch)
Crankshaft Pulley Bolt
CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage.
First pass 90 Nm (66 lb-ft).
Second pass Loosen one full turn
Third pass 50 Nm (37 lb-ft).
Final pass Tighten an additional 90° without exceeding 200 Nm (148 lb-ft).