Cylinder Block Assembly
CYLINDER BLOCK DIMENSIONSCylinder Bore Diameter:
Standard
Mark 1 100.000 - 100.010 mm (3.9370 - 3.9374 inch)
Mark 2 100.010 - 100.020 mm (3.9374 - 3.9378 inch)
Mark 3 100.020 - 100.030 mm (3.9378 - 3.9382 inch)
Maximum
STD 100.23 mm (3.9461 inch)
O/S 0.50 100.73 mm (3.9658 inch)
O/S 1.00 101.23 mm (3.9854 inch)
Surface Warpage:
Maximum 0.05 mm (0.0020 inch)
CRANKSHAFT DIMENSIONS
Thrust Clearance
STD 0.020 - 0.220 mm (0.0008 - 0.0087 inch)
Maximum 0.300 mm (0.0118 inch)
Main Journal Diameter
STD 68.982 - 69.000 mm (2.7158 - 2.7165 inch)
U/S 0.25 68.745 - 68.755 mm (2.7065 - 2.7069 inch)
Crank Pin Diameter
STD 56.982 - 57.000 mm (2.2434 - 2.2441 inch)
U/S 0.25 56.745 - 56.755 mm (2.2341 - 2.2344 inch)
Circle Runout
Maximum 0.06 mm (0.0024 inch)
Main Journal Taper And Out-Of-Round
Maximum 0.02 mm (0.0008 inch)
Crank Pin Taper And Out-of-round
Maximum 0.02 mm (0.0008 inch)
CRANKSHAFT MAIN BEARING
Thrust Washer Thickness
STD 2.440 - 2.490 mm (0.0961 - 0.0980 inch)
O/S 0.125 2.503 - 2.553 mm (0.0985 - 0.1005 inch)
O/S 0.250 2.565 - 2.615 mm (0.1010 - 0.1030 inch)
Main Journal Oil Clearance
STD 0.036 - 0.054 mm (0.0014 - 0.0021 inch)
U/S 0.25 0.035 - 0.075 mm (0.0014 - 0.0030 inch)
Maximum 0.10 mm (0.0039 inch)
Main Bearing Center Wall Thickness
STD
Mark 2 2.492 - 2.495 mm (0.0981 - 0.0982 inch)
Mark 3 2.495 - 2.498 mm (0.0982 - 0.0983 inch)
Mark 4 2.498 - 2.501 mm (0.0983 - 0.0985 inch)
Mark 5 2.501 - 2.504 mm (0.0985 - 0.0986 inch)
Mark 6 2.504 - 2.507 mm (0.0986 - 0.0987 inch)
CRANKSHAFT MAIN BEARING REMOVAL/TIGHTENING SEQUENCE
Main Bearing Cap Bolts Removal Sequence
Main Bearing Cap Bolts Tightening Sequence
CRANKSHAFT MAIN BEARING TIGHTENING SPECIFICATIONS
Main Bearing Cap To Cylinder Block:
1st Pass 74 Nm (54 ft. lbs.)
2nd Pass Turn additional 90°
Main Bearing Bolt Diameter
Standard Outside Diameter 10.85-11.00 mm (0.4272-0.4331 in.)
Minimum Outside Diameter 10.6 mm (0.417 in)
CONNECTING ROD DIMENSIONS
Clearance:
Oil:
Standard 0.032 - 0.050 mm (0.0013 - 0.0020 inch)
U/S 0.25 0.033 - 0.073 mm (0.0013 - 0.0029 inch)
Maximum 0.10 mm (0.0039 inch)
Piston Pin Oil:
Standard 0.004 - 0.012 mm (0.0002 - 0.0005 inch)
Maximum 0.05 mm (0.0020 inch)
Thrust:
STD 0.160 - 0.262 mm (0.0063 - 0.0103 inch)
Maximum 0.362 mm (0.0143 inch)
Diameter:
Bushing Inside 26.008 - 26.020 mm (1.0239 - 1.0244 inch)
Bolt Outside:
Standard 8.40 - 8.60 mm (0.3307 - 0.3386 inch)
Minimum 8.00 mm (0.3150 inch)
Piston Pin 26.000 - 26.012 mm (1.0236 - 1.0241 inch)
Rod:
Bend:
Maximum Per 100 mm (3.94 inch) 0.05 mm (0.0020 inch)
Twist:
Maximum Per 100 mm (3.94 inch) 0.15 mm (0.0059 inch)
Thickness:
Bearing Center Wall:
Standard:
Mark 2 1.744 - 1.747 mm (0.0687 - 0.0688 inch)
Mark 3 1.747 - 1.750 mm (0.0688 - 0.0689 inch)
Mark 4 1.750 - 1.753 mm (0.0689 - 0.0690 inch)
Mark 5 1.753 - 1.756 mm (0.0690 - 0.0691 inch)
Mark 6 1.756 - 1.759 mm (0.0691 - 0.0693 inch)
CONNECTING ROD TIGHTENING SPECIFICATIONS
Rod Cap To Connecting Rod
1st Pass 48 Nm (35 ft. lbs.)
2nd Pass Turn Additional 90°
PISTON ASSEMBLY
Piston Ring End Gap
Standard:
No. 1 0.300 - 0.520 mm (0.0118 - 0.0205 inch)
No. 2 0.450 - 0.670 mm (0.0177 - 0.0264 inch)
Oil 0.150 - 0.520 mm (0.0059 - 0.0205 inch)
Maximum:
No. 1 1.120 mm (0.0441 inch)
No. 2 1.170 mm (0.0461 inch)
Oil 1.120 mm (0.0441 inch)
Ring Groove Clearance:
No. 1 0.040 - 0.060 mm (0.0016 - 0.0024 inch)
No. 2 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Piston Diameter:
STD
Mark 1 99.950 - 99.960 mm (3.9350 - 3.9354 inch)
Mark 2 99.960 - 99.970 mm (3.9354 - 3.9358 inch)
Mark 3 99.970 - 99.980 mm (3.9358 - 3.9362 inch)
O/S 0.50 100.450 - 100.480 mm (3.9547 - 3.9559 inch)
O/S 1.00 100.950 - 100.980 mm (3.9744 - 3.9756 inch)
Piston To Cylinder Oil Clearance:
STD 0.040 - 0.060 mm (0.0016 - 0.0024 inch)
CRANKSHAFT PULLEY TIGHTENING SPECIFICATIONS
Crankshaft Pulley To Crankshaft 412 Nm (304 ft. lbs.)