System Specifications

The cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches longer than 0.0254 mm (0.001 inch).

Cylinder bore
Diameter
Grade 1 90.200-90.210 mm (3.5512-3.5516 inch)
Grade 2 90.210-90.220 mm (3.5516-3.5520 inch)
Grade 3 90.220-90.230 mm (3.5520-3.5524 inch)
Maximum taper 0.006 mm (0.0002 inch)
Maximum out-of-round 0.020 mm (0.0008 inch)
Main bearing bore inside diameter 72.400-72.424 mm (2.850-2.851 inch)
Crankshaft
Main bearing journal
Diameter 67.481-67.505 mm (2.6567-2.6576 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round between cross sections 0.0075 mm (0.0003 inch)
Journal-to-cylinder block clearance 0.048-0.024 mm (0.0019-0.0009 inch)
Connecting rod journal
Diameter 53.003-52.983 mm (2.0867-2.0859 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round between cross sections 0.0075 mm (0.0003 inch)
Crankshaft maximum end play 0.075-0.377 mm (0.0030-0.0148 inch)
Piston and Connecting Rod
Piston diameter (at right angle to pin bore)
Grade 1 90.175-90.165 mm (3.5502-3.5498 inch)
Grade 2 90.185-90.175 mm (3.5506-3.5502 inch)
Grade 3 90.195-90.185 mm (3.5510-3.5506 inch)
Piston-to-cylinder bore clearance (at grade size) 0.025-0.045 mm (0.0010-0.0018 inch)
Ring end gap
Top 0.15-0.30 mm (0.006-0.012 inch)
Intermediate 0.25-0.50 mm (0.0098-0.0197 inch)
Oil control 0.15-0.65 mm (0.0059-0.0256 inch)
Ring groove width
Top 1.52-1.55 mm (0.0598-0.0610 inch)
Intermediate 1.52-1.54 mm (0.0598-0.0606 inch)
Oil control 3.030-3.050 mm (0.1193-0.1201 inch)
Ring width
Top and intermediate 1.50-1.47 mm (0.0590-0.0578 inch)
Ring-to-groove clearance
Top 0.020-0.080 mm (0.0008-0.0031 inch)
Intermediate 0.030-0.070 mm (0.0012-0.0028 inch)
Pin bore diameter 22.008-22.014 mm (0.8665-0.8667 inch)
Pin diameter 22.0010-22.0030 mm (0.8662-0.8663 inch)
Pin length 61.8 mm (2.43 3 inch)
Pin-to-piston fit 0.005-0.013 mm (0.0002-0.0005 inch)
Rod-to-pin clearance 0.009-0.0235 mm (0.0004-0.0093 inch)
Rod pin bore diameter 22.012-22.024 mm (0.8666-0.8671 inch)
Rod length (center-to-center) 169.1 mm (6.6575 inch)
Rod maximum allowed bend 0.038 mm (0.0015 inch)
Rod maximum allowed twist 0.05 mm (0.0020 inch) b
Rod bearing bore diameter (with assembled liners) 53.049-53.027 mm (2.0885-2.0877 inch)
Rod bearing-to-crankshaft clearance 0.064-0.026 mm (0.0025-0.0010 inch)
Rod side clearance 0.475-0.125 mm (0.0187-0.0049 inch)

b 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.








Main bearing size chart





Vertical main bearing cap bolts
First pass 40 Nm (30 ft. lbs.)
Final pass tighten 90°





Side main bearing bolts
First pass 30 Nm (22 ft. lbs.)
Final pass tighten 90°

Crankshaft Pulley Bolt: Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
First pass 90 Nm (66 ft. lbs.)
Second pass loosen 360°
Third pass 50 Nm (37 ft. lbs.)
Final pass tighten 90°