System Specifications
CYLINDER BLOCKHead gasket surface flatness
0.50 mm (0.002 inch) for 150 x 150 mm (5 x 5 inch) area
0.25 mm (0.001 inch) for 25 x 25 mm (1 x 1 inch) area
0.120 mm (0.005 inch) overall
Head gasket thickness 1.0mm (.40 inch)
Main bearing bore diameter 67.998-68.022mm (2.677-2.6780 inch)
Cylinder bore
Diameter
Cylinder Bore Diameter Grade 1: 89.000-89.010 mm (3.50393-3.504323 inch)
Grade 2: 89.010-89.020 mm (3.504323-3.504717 inch)
Grade 3: 89.020-82.030 mm (3.504717-3.50511 inch)
Out-of-round limit 0.015 mm (.0005 inch)
Out-of-round service limit 0.020 mm (.0007 inch)
Taper service limit 0.020 mm (0.008 inch)
CRANKSHAFT
Main bearing journal diameter; 62.968-62.992 mm (2.467-2.479 inch)
Connecting journal diameter; 49.970-49.990 mm (1.967-1.968 inch)
Crankshaft free end play; 0.110-0.232 mm (0.004-0.009 inch)
Crankshaft runout to rear face of cylinder block; 0.050mm (0.001 inch) Max
Connecting rod bearings
Clearance to crankshaft (0.028-0.066mm 0.001-0.0025 inch)
Bearing wall thickness-standard (0.250 mm Undersize-Add 0.125 mm to standard or grade 2 thickness.); 1.503 mm (.059 inch)
Main bearings
Clearance to crankshaft-desired; 0.025-0.045 mm (0.0009-0.0017 inch)
Clearance to crankshaft-allowable; 0.025-0.050mm (0.0009-0.0019 inch)
Bearing wall thickness-grade 1; 2.497mm (0.0983 inch)
Bearing wall thickness-grade 2 (0.250mm Undersize-Add 0.12 mm to standard or grade 2 thickness.); 2.501mm (0.0985 inch)
Bearing wall thickness-grade 3; 2.505mm (0.0986 inch)
CONNECTING ROD
Piston pin bore diameter; 21.017-21.031 mm (0.827-0.828 inch)
Crankshaft bearing bore diameter; 53.015-53.035mm (2.0872-2.0879 inch)
Length (center to center) 138.06-138.14mm (5.435-5.38 inch)
Alignment (bore to bore max difference); Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.
Twist 0.050 mm per 25 (0.0019 per 0.984 inch)
Band 0.038 mm per 25 (0.0014 per 0.984 inch)
Side clearance (assembled to crank)
Standard 0.100-0.30mm (0.0039-0.0118 inch)
Service limit 0.35mm (0.0137 inch) Max
PISTON
Piston diameter (Measured at 50 mm (1.9685 inch) from outer perimeter top of piston to the pin axis.)
Coated grade 1 88.990-89.010mm (3.5035-3.5043 inch)
Coated grade 2 88.998-89.022mm (3.5039-3.5048 inch)
Coated grade 3 89.010-89.030mm (3.5043-3.5051 inch)
Uncoated grade 1 88.970-88.980mm (3.50275-3.50314 inch)
Uncoated grade 2 88.978-88.992mm (3.50306-3.50362 inch)
Uncoated grade 3 89.010-89.030mm (3.50432-3.50511 inch)
Piston to bore clearance 0.012 to 0.022mm (0.0005-0.0009 inch)
Pin bore diameter (piston) 21.008-21.012mm (0.8270-0.8272 inch)
Ring groove width
Compression (top) 1.230-1.245mm (0.0484-0.0490 inch)
Compression (bottom) 1.530-1.545mm (0.0602-0.0608 inch)
Oil ring 3.030-3.055mm (0.1192-0.0120 inch)
Piston pin
Length 60.51-60.08mm (2.382-2.365 inch)
Diameter 21.011-21.013mm (0.0013 inch)
Pin to piston clearance -0.005 to +0.001 mm (0.0001-0.00003 inch)
Pin to rod clearance
Standard 0.004-0.020mm (0.0001-0.0007 inch)
Service limit 0.035mm (0.0013 inch)
Side clearance
Compression (top) 0.040-0.075mm (0.0015-0.0029 inch)
Compression (bottom) 0.040-0.085mm (0.0015-0.0033 inch)
Oil ring Snug Fit
Service limit 0.10mm (0.0039 inch)
Compression (top)-service limit 0.50mm (0.0196 inch) Max
Compression (bottom)-service limit 0.65mm (0.0255 inch) Max
Oil ring (steel rail)-service limit 0.90mm (0.0354 inch) Max
Piston ring gap (Specification 82.4 mm (3.2441 inch) diameter gauge.)
Compression (top)-gauge diameter 0.100-0.250mm (0.0039-0.0098 inch)
Compression (bottom)-gauge diameter 0.27-0.42mm (0.0106-0.0165 inch)
Oil ring (steel rail)-gauge diameter 0.15-0.65mm (0.0059-0.0255 inch)
Compression (top)-service limit 0.50mm (0.0196 inch) Max
Compression (bottom)-service limit 0.65mm (0.0255 inch) Max
Oil ring (steel rail)-service limit 0.90mm (0.0354 inch) Max
Torque Specifications
For specifications regarding Main Bearing Cap bolts, refer to service procedure. Assembly (1 - 50)
For specifications regarding Rod Bearing Cap bolts, refer to service procedure. Assembly (1 - 50)
For specifications regarding Crankshaft Pulley bolt, refer to service procedure. Service and Repair