System Specifications
Cylinder bore diameter-surface finish (RMS) d 0.2-0.6 micronsCylinder bore diameter-out-of-round limit d 0.015 mm (0.0006 inch)
Cylinder bore diameter-out-of-round service limit d 0.020 mm (0.0008 inch)
Cylinder bore diameter-taper service limit d 0.006 mm (0.0002 inch)
Cylinder bore maximum taper 0.006 mm (0.0002 inch)
Cylinder bore maximum out-of-round 0.015 mm (0.0006 inch)
Main bearing bore inside diameter 72.400-72.424 mm (2.8504-2.8513 inch)
Head gasket surface flatness 0.15 mm (0.006 inch) max. overall
Camshaft bearing bore inside diameter 26.987-27.012 mm (1.0625-1.0635 inch)
Connecting rod bearing bore diameter 56.866-56.886 mm (2.23881-2.23960 inch)
Connecting rod bearing-to-crankshaft clearance-desired and allowable 0.027-0.069 mm (0.0010629-0.0027165 inch)
Connecting rod side clearance (assembled to crank)-standard 0.15-0.45 mm (0.00591-0.01772 inch)
Connecting rod side clearance (assembled to crank)-service limit 0.50 mm (0.01969 inch) max.
Piston diameter-standard e 0.028 mm (0.0010 inch)
Piston diameter - coded red 1 e 90.167-90.188 mm (3.299-3.5505 inch)
Piston diameter - coded blue 2 e 90.180-90.195 mm (3.5504-3.5510 inch)
Piston diameter - coded yellow 3 e 90.198-90.208 mm (3.5511-3.5515 inch)
Piston-to-cylinder bore-clearance -0.010 ±0.026 mm (-0.0003937 ±0.0010236 inch)
Main bearing journal diameter 67.481-67.505 mm (2.6567269-2.6576718 inch)
Main bearing journal maximum taper l0.004 mm (0.0002 inch)
Main bearing journal maximum out-of-round 0.006 mm (0.0002 inch)
Main bearing journal-to-cylinder block clearance-desired 0.025-0.045 mm (0.00098-0.00177 inch)
Main bearing journal-to-cylinder block clearance-allowable 0.025-0.050 mm (0.00098-0.00197 inch)
Piston ring end gap compression (top) f 0.150-0.300 mm (0.006-0.0018 inch)
Piston ring end gap-compression (bottom) f 0.300-0.550 mm (0.0018-0.0022 inch)
Piston ring end gap - oil ring (steel rail) f 0.15-0.66 mm (0.00591-0.02598 inch)
Piston ring groove width - compression (top) 1.230-1.250 mm (0.484-0.0492 inch)
Piston ring groove width - compression (bottom) 1.520-1.540 mm (0.05984-0.06062 inch)
Piston ring groove width - oil ring 3.030-3.055 mm (0.1 193-0.1203 inch)
Piston ring width-compression (top and bottom) 1.00 mm (0.03937 in)max.
Piston ring width-oil ring 1.15 mm (0.04528 inch) max.
Piston ring-to-groove clearance-compression (top) 0.0090-0.0235 mm (0.000354-0.000925 inch)
Piston ring-to-groove clearance-compression (bottom) 0.030-0.080 mm (0.00118-0.00315 inch)
Piston ring-to-groove clearance-oil ring snug fit
d Cylinder bore diameter
e Measured at 42 mm from piston dome, at 90 degrees to the piston pin.
f Specification in 90.200 mm diameter gauge.
Red-90.200-90.213
Blue-90.213-90.226
Yellow-90.226-90.239
Upper main bearing caps
Loosely install the main caps and the bolts
Tighten bolts 1-20 in the sequence shown in four stages.
1: Tighten 10 Nm (89 inch lbs.)
2: Tighten 25 Nm (18 ft. lbs.)
3: Tighten 40 Nm (30 ft. lbs.)
4: Tighten an additional 90 degrees
Lower main bearings caps
Install and tighten the cross-mounted bolts in two stages.
1: Tighten 40 Nm (30 ft. lbs.)
2: Tighten an additional 90 degrees
Connecting rod bearing caps and bolts and tighten in three stages.
1: Tighten 25 Nm (18 ft. lbs.)
2: Tighten 45 Nm (33 ft. lbs.)
3: Tighten an additional 90 degrees
Crankshaft Pulley bolt
Tighten the bolt in four stages:
1: Tighten 90 Nm (66 ft. lbs.)
2: Loosen one full turn.
3: Tighten 50 Nm (37 ft. lbs.).
4: Tighten an additional 90 degrees without exceeding 200 Nm (148 ft. lbs.).