System Specifications
BlockCrankshaft Main Bearing Bore Diameter 77.0-77.024 mm (3.031-3.032 in)
Cylinder Bore Diameter - Production 89.0-89.015 mm (3.5039-3.5045 in)
Cylinder Bore Diameter - Service 89.065 mm (3.5065 in)
Cylinder Bore Diameter - 0.25 mm (0.0098 in) Oversize Piston 89.25-89.265 mm (3.5138-3.5144 in)
Cylinder Bore Taper - Service 0.05 mm (0.002 in)
Cylinder Head Deck Surface Flatness - Production 0.07 mm (0.003 in)
Cylinder Head Deck Surface Flatness - Service 0.1 mm (0.004 in)
Cylinder Reboring Limit - Service 0.25 mm (0.01 in)
Rear Housing-to-Oil Seal Clearance 0.5-0.8 mm (0.019-0.031 in)
Connecting Rod
Bearing Clearance - Production 0.02-0.044 mm (0.0008-0.0017 in)
Bearing Clearance - Service 0.05 mm (0.002 in)
Bore Diameter - Bearing End 58 mm (2.28 in)
Bore Diameter - Pin End 21.97-21.976 mm (0.865-0.8652 in)
Bore Out-of-Round - Bearing End 0.005 mm (0.0002 in)
Length 158.5 mm (6.24 in)
End Play - Production 0.15-0.35 mm (0.006-0.014 in)
End Play - Service 0.45 mm (0.018 in)
Connecting Rod Bolt - Difference in Diameter - Service 0.0-0.1 mm (0.0-0.004 in)
Crankshaft)
Connecting Rod Journal Diameter 54.976-55.0 mm (2.1644-2.1654 in)
Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 in)
Connecting Rod Journal Out-of-Round - Service 0.01 mm (0.0004 in)
Connecting Rod Journal Taper - Production 0.005 mm (0.0002 in)
Connecting Rod Journal Taper - Service 0.01 mm (0.0004 in)
Connecting Rod Journal Width 17.55-17.75 mm (0.691-0.699 in)
End Play - Production 0.1-0.35 mm (0.004-0.014 in)
End Play - Service 0.45 mm (0.018 in)
Main Bearing Clearance - Production 0.02-0.044 mm (0.0008-0.0017 in)
Main Bearing Clearance - Service 0.05 mm (0.002 in)
Main Journal Diameter 71.976-72.0 mm (2.8337-2.8346 in)
Main Journal Out-of-Round - Production 0.005 mm (0.0002 in)
Main Journal Out-of-Round - Service 0.01 mm (0.0004 in)
Main Journal Taper - Production 0.005 mm ( 0.0002 in)
Main Journal Taper - Service 0.01 mm (0.0004 in)
Runout - Production - Journals 1 and 4 0.02 mm (0.0008 in)
Runout - Production - Journals 2 and 3 0.025 mm (0.001 in)
Runout - Service 0.03 mm (0.0012 in)
Thrust Surface Distance 0.1-0.35 mm (0.004-0.014 in)
Thrust Surface Runout 0.45 mm (0.018 in)
Piston Rings
End Gap - Top - Production 0.2-0.35 mm (0.008-0.014 in)
End Gap - Top - Service 0.6 mm (0.024 in)
End Gap - Second - Production 0.4-0.55 mm (0.0016-0.022 in)
End Gap - Second - Service 0.7 mm (0.028 in)
End Gap - Oil - Production 0.2-0.7 mm (0.008-0.028 in)
End Gap - Oil - Service 0.8 mm (0.031 in)
First Compression Ring - Production 0.02-0.35 mm (0.008-0.014 in)
First Compression Ring - Service 0.6 mm (0.024 in)
Second Compression Ring - Production 0.4-0.055 mm (0.0016-0.0022 in)
Second Compression Ring - Service 0.7 mm (0.028 in)
Oil Control Ring - Production 0.2-0.7 mm (0.008-0.028 in)
Oil Control Ring - Service 0.8 mm (0.031 in)
Piston Ring-to-Groove Clearance - Top - Production 0.055-0.08 mm (0.0022-0.0031 in)
Piston Ring-to-Groove Clearance - Top - Service 0.15 mm (0.006 in)
Piston Ring-to-Groove Clearance - Second - Production 0.03-0.055 mm (0.0012-0.0022 in)
Piston Ring-to-Groove Clearance - Second - Service 0.13 mm (0.005 in)
First Compression Ring - Production 0.055-0.08 mm (0.0022-0.0031 in)
First Compression Ring - Service 0.13 mm (0.005 in)
Second Compression Ring - Production 0.03-0.055 mm (0.0012-0.0022 in)
Second Compression Ring - Service 0.13 mm (0.005 in)
First Compression Ring Height 1.2 mm (0.05 in)
First Compression Width 3.1 mm (0.12 in)
Second Compression Height 1.2 mm (0.05 in)
Second Compression Width 3.4 mm (0.13 in)
Pistons
Diameter - Production - Measure 16 mm (0.63 in) from Bottom of Skirt 88.975-88.985 mm (3.5029-3.5033 in)
Diameter - Service 88.965 mm (3.5026 in)
Diameter - 0.25 mm (Oversize Piston 89.225-89.235 mm (3.5128-3.5132 in)
Out-of-Round - Measured by Clearance to Cylinder Bore 0.08 mm (3.15 in)
Pin Bore Diameter 21.96-22.03 mm (0.864-0.867 in)
Ring Groove Width - Top - Production 1.24-1.25 mm (0.0488-0.0492 in)
Ring Groove Width - Top - Service 1.27 mm (0.05 in)
Ring Groove Width - Second - Production 1.22-1.23 mm (0.048-0.0484 in)
Ring Groove Width - Second - Service 1.25 mm (0.049 in)
Ring Groove Width - Oil - Production 2.805-2.825 mm (0.1104-0.1112 in)
Ring Groove Width - Oil - Service 2.85 mm (0.112 in)
Piston to Bore Clearance - Production 0.015-0.04 mm (0.0006-0.0016 in)
Piston to Bore Clearance - Service 0.08 mm (0.003 in)
Piston Pin)
Clearance to Connecting Rod Bore - Production 0.005-0.014 mm ( 0.0002-0.0006 in)
Clearance to Connecting Rod Bore - Service 0.019 mm (0.0007 in)
Clearance to Piston Pin Bore - Production -0.005 to +0.001 mm (-0.0002 to +0.00004 in)
Clearance to Piston Pin Bore - Service 0.004 mm (0.0002 in)
Diameter - Production 21.962-21.965 mm (0.8646-0.8648 in)
Diameter - Service 21.954 mm (0.8643 in)
Length 53.77-54.23 mm (2.116-2.135 in)
Connecting Rod Cap Bolts - First Pass 20 N.m (14 lb ft)
Connecting Rod Cap Bolts - Final Pass 90 degrees
Crankshaft Balancer Bolt - First Pass 64 N.m (47 lb ft)
Crankshaft Balancer Bolt - Final Pass 60 degrees
Crankshaft Main Bearing Cap Bottom M11 Bolts 74 N.m (54 lb ft)
Crankshaft Main Bearing Cap Side M10 Bolts 49 N.m (36 lb ft)