System Specifications
Cylinder BlockCylinder bore
Diameter 98.191 - 98.209 mm (3.866-3.867 inch)
Maximum taper 0.076 mm (0.003 inch)
Maximum out-of-round 0.05 mm (0.002 inch)
Main bearing bore inside diameter 85.99-86.01 mm (3.3854-3.3862 inch)
Camshaft bearing bore inside diameter 65.98-66.02 mm (2.5976-2.5992 inch)
Head gasket surface flatness
0.13 mm (0.005 inch) across the total area
0.030 mm (0.0011 inch) around fire rings and oil drain holes at 25 mm (0.98 inch) length
00.35 mm (0.0014 inch) around water jacket holes at 25 mm (0.98 inch) length
0.060 mm (0.0024 inch) around push rod opening at 25 mm (0.98 inch) length
Crankshaft
Maximum end play 0.076-0.328 mm (0.003-0.013 inch)
Main bearing journal
Diameter
Standard size 80.9873-81.0127 mm (3.188-3.189 inch)
0.254 mm (0.010 inch) undersize 80.7333-80.7587 mm (3.178-3.179 inch)
0.508 mm (0.020 inch) undersize 80.4793-80.5047 mm (3.168-3.169 inch)
0.762 mm (0.030 inch) undersize 80.2253-80.2507 mm (3.158-3.159 inch)
Maximum taper 0.009 mm (0.0003 inch)
Maximum out-of-round 0.006 mm (0.0002 inch)
Clearance to cylinder block 0.014-0.090 mm (0.0006-0.0035 inch)
Connecting rod journal
Diameter
Standard size 71.9873 to 72.0127 mm (2.834 to 2.835 inch)
0.253 mm (0.010 inch) undersize 71.7333 to 71.7587 mm (2.824 to 2.825 inch)
0.508 mm (0.020 inch) undersize 71.4793 to 71.5047 mm (2.814 to 2.815 inch)
0.762 mm (0.030 inch) undersize 71.2253 to 71.2507 mm (2.804 to 2.805 inch)
Maximum taper 0.017 mm (0.007 inch)
Maximum out-of-round 0.006 mm (0.0002 inch)
Lower Crankcase Main Bearing Mounting Bolts
Make sure longer main cap bolts (M14 x 2 x 127) are installed inboard and shorter bolts (M14 x 2 x 114) are installed outboard.
First pass 149 Nm (110 lb-ft).
Second pass 176 Nm (130 lb-ft).
Final pass 231 Nm (170 lb-ft).
Connecting Rod
Clearance to pin 0.058-0.041 mm (0.0023-0.0016 inch)
Pin bore diameter 38.542-38.550 mm (1.517-1.577 inch)
Length (center-to-center) 176 mm (6.929 inch)
Maximum allowed bend 0.025 mm (0.001 inch)
Maximum allowed twist 0.05 mm (0.002 inch)
Rod bearing bore diameter 75.987-76.013 mm (2.9916-2.9926 inch)
Bearing-to-crankshaft clearance 0.0152-0.089 mm (0.0006-0.0035 inch)
Rod side clearance 0.230-1.067 mm (0.009-0.042 inch)
Connecting Rod Cap Bolts
First pass 45 Nm (33 lb-ft).
Final pass 68 Nm (50 lb-ft).
Piston
Diameter
Standard size 98.114-98.146 mm (3.8630-3.8640 inch)
0.254 mm (0.010 inch) oversize 98.368-98.400 mm (3.8730-3.8740 inch)
0.508 mm (0.020 inch) oversize 98.622-98.654 mm (3.8830-3.8840 inch)
0.762 mm (0.030 inch) oversize 98.876-98.908 mm (3.8930-3.8940 inch)
Clearance to cylinder bore 0.045-0.095 mm (0.0018-0.0037 inch)
Ring end gap
Top compression 0.29-0.79 mm (0.011-0.031 inch)
Intermediate compression 1.42-1.930 mm (0.056-0.076 inch)
Oil control 0.24-0.737 mm (0.009-0.029 inch)
Ring groove width
Upper limit - (measured over 2.10 mm (0.082 inch) gauge pins) 96.606 mm (3.8034 inch)
Replacement limit - (measured over 2.10 mm (0.082 inch) gauge pins) 96.406 mm (3.7955 inch)
Piston ring width 1.990-1.969 mm (0.078-0.077 inch)
Piston ring-to-groove clearance
Intermediate 0.050-0.096 mm (0.0020-0.0038 inch)
Oil controlling 0.040-0.095 mm (0.0015-0.0037 inch)
Piston pin
Bore diameter 38.511-38.512 mm (1.5162-1.5165 inch)
Pin diameter 38.491-38.501 mm (1.5154-1.5158 inch)
Pin length 74.6-75 mm (2.937-2.953 inch)
Fit to piston 0.011-0.027 mm (0.0004-0.0011 inch)
Crankshaft Pulley Bolts
Install 4 new bolts
First pass 68 Nm (50 lb-ft)
Final pass Tighten an additional 90°