System Specifications
CYLINDER BLOCKMaximum warpage 0.07 mm (0.0028 in.)
Mark 1: Standard diameter 94.002 to 94.010 mm (3.7009 to 3.7012 in.)
Mark 2: Standard diameter 94.010 to 94.023 mm (3.7012 to 3.7017 in.)
Mark 3: Standard diameter 94.023 to 94.031 mm (3.7017 to 3.7020 in.)
Maximum diameter 94.230 mm (3.7098 in.)
CYLINDER HEAD SET BOLT
Standard outside diameter 9.810 to 9.960 mm (0.3862 to 0.3921 inch)
Minimum outside diameter 9.70 mm (0.3819 inch)
CRANKSHAFT
Standard thrust clearance 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Maximum thrust clearance 0.30 mm (0.0118 in.)
Thrust washer thickness 2.440 to 2.490 mm (0.0961 to 0.0980 in.)
No. 1 and No. 5 Standard clearance 0.028 to 0.046 mm (0.0011 to 0.0018 in.)
Others Standard clearance 0.040 to 0.058 mm (0.0016 to 0.0023 in.)
No. 1 and No. 5 Maximum clearance 0.065 mm (0.0026 in.)
Others Maximum clearance 0.065 mm (0.0026 in.)
Maximum circle runout 0.04 mm (0.0016 in.)
Main journal diameter 66.988 to 67.000 mm (2.6373 to 2.6378 in.)
Crank pin diameter 51.982 to 52.000 mm (2.0465 to 2.0472 in.)
Maximum taper and out of round 0.02 mm (0.0008 in.)
CRANKSHAFT BEARING CAP BOLT
Standard diameter 10.760 to 10.970 mm (0.4236 to 0.4319 in.)
Maximum diameter 10.40 mm (0.4094 in.)
MAIN BEARING CAPS
If any one of the bearing cap bolts is broken or deformed, replace it.
Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
Install and uniformly tighten the 10 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.
Torque 27 Nm (275 kgf-cm, 20 ft. lbs.)
If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.
Mark the front of the crankshaft bearing cap bolt's head with paint.
Tighten the crankshaft bearing cap bolts another 90° as shown in the illustration.
Check that the painted mark is now at a 90° angle to the front.
Check that the crankshaft turns smoothly
CONNECTING ROD
Standard thrust clearance 0.160 to 0.290 mm (0.0063 to 0.0114 in.)
Maximum thrust clearance 0.35 mm (0.0138 in.)
Standard oil clearance 0.021 to 0.047 mm (0.0008 to 0.0019)
Maximum oil clearance 0.059 mm (0.0023 in.)
Maximum bend 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Maximum twist 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
PISTON
Mark 1: Piston diameter 93.902 to 93.912 mm (3.6969 to 3.6973 in.)
Mark 2: Piston diameter 93.912 to 93.920 mm (3.6973 to 3.6976 in.)
Mark 3: Piston diameter 93.920 to 93.930 mm (3.6976 to 3.6980 in.)
Standard oil clearance 0.090 to 0.111 mm (0.0035 to 0.0044 in.)
Maximum oil clearance 0.13 mm (0.0051 in.)
Piston pin diameter 21.997 to 22.009 mm (0.8660 to 0.8664 in.)
PISTON RING
No. 1 Ring groove clearance 0.030 to 0.080 mm (0.0012 to 0.0031 in.)
No. 2 Ring groove clearance 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
No. 1 Standard end gap 0.300 to 0.400 mm (0.0118 to 0.0158 in.)
No. 2 Standard end gap 0.400 to 0.550 mm (0.0158 to 0.0217 in.)
Oil (side rail) Standard end gap 0.130 to 0.380 mm (0.0051 to 0.0150 in.)
No. 1 Maximum end gap 1.10 mm (0.0433 in.)
No. 2 Maximum end gap 1.30 mm (0.0512 in.)
Oil (side rail) Maximum end gap 0.90 mm (0.0354 in.)