System Specifications
Block^ Crankshaft Main Bearing Bore Diameter 72.430 - 72.442 mm (2.8516 - 2.8521 inch)
^ Crankshaft Main Bearing Bore Out-of-Round 0.010 mm (0.0004 inch)
^ Crankshaft Main Rear Oil Seal
^ Bore 115.962 - 116.038 mm (4.5654 - 4.5684 inch)
^ Runout 0.250 mm (0.0098 inch)
^ Cylinder Bore Diameter 41 mm (1.610 inch) Below Deck Face 92.992 - 93.008 mm (3.6611 - 3.6617 inch)
^ Cylinder Bore Out-of-Round
^ Production 0.010 mm (0.0004 inch)
^ Service 0.100 mm (0.0039 inch)
^ Cylinder Bore Taper
^ Production 0.010 mm (0.0004 inch)
^ Service 0.100 mm (0.0039 inch)
^ Cylinder Head Deck Height 224.55 mm (8.8406 inch)
^ Cylinder Head Deck Surface Flatness 0.100 mm (0.0039 inch)
Crankshaft Balancer Bolt
^ First Pass 50 Nm (37 ft. lbs. )
^ Final Pass +150 degrees
Lower Crankcase
^ Bearing Bolt
^ M10 x 1.5 First Pass - (1-20) In Sequence 20 Nm (15 ft. lbs.)
^ M10 x 1.5 Final Pass - (1-20) In Sequence +65 degrees
^ Perimeter Bolt
^ M8 x 1.25 - In Sequence 30 Nm (22 ft. lbs.)
Connecting Rod Bolts - First Pass 20 Nm (15 ft. lbs.)
Connecting Rod Bolts - Final Pass 75 degrees
Connecting Rod
Connecting Rod Bearing Clearance - Production 0.023 - 0.065 mm (0.0009 - 0.0025 inch)
Connecting Rod Bearing Clearance - Service 0.023 - 0.076 mm (0.0009 - 0.003 inch)
Connecting Rod Bore Diameter - Bearing End 56.505 - 56.525 mm (2.224 - 2.225 inch)
Connecting Rod Bore Out-of-Round - Bearing End - Production 0.004 - 0.008 mm (0.00015 - 0.0003 inch)
Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004 - 0.008 mm (0.00015 - 0.0003 inch)
Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 inch)
Crankshaft
^ Connecting Rod Journal Diameter 53.947 - 53.963 mm (2.1239 - 2.1245 inch)
^ Connecting Rod Journal Out-of-Round 0.005 mm (0.0002 inch)
^ Connecting Rod Journal Taper 0.005 mm (0.0002 inch)
^ Connecting Rod Journal Width 43.840 - 43.960 mm (1.7260 - 1.7307 inch)
^ Crankshaft Balancer
^ Surface Diameter 50.730 - 50.870 mm (1.9972 - 2.0028 inch)
^ Hub Inside Diameter 34.847 - 34.864 mm (1.3719 - 1.3726 inch)
^ Crankshaft End Play 0.050 - 0.500 mm (0.0020 - 0.0197 inch)
^ Crankshaft Main Bearing Clearance
^ Production 0.0150 - 0.0550 mm (0.0006 - 0.0022 inch)
^ Service 0.0150 - 0.0635 mm (0.0006 - 0.0025 inch)
^ Crankshaft Main Journal Diameter 64.350 - 64.366 mm (2.5335 - 2.5341 inch)
^ Crankshaft Main Journal Out-of-Round 0.005 mm (0.0002 inch)
^ Crankshaft Main Journal Taper 0.005 mm (0.0002 inch)
^ Crankshaft Main Journal Thrust Wall Runout 0.040 mm (0.0016 inch)
^ Crankshaft Main Journal Thrust Wall Square 0.010 mm (0.0004 inch)
^ Crankshaft Main Journal Width, #1, #2, #4, #5 24.540 - 24.660 mm (0.9661 - 0.9709 inch)
^ Crankshaft Main Journal Width, Thrust #3 25.150 - 25.250 mm (0.9902 - 0.9941 inch)
^ Crankshaft Nose Diameter
^ From Front Face 0.00 - 21.00 mm (0.0000 - 0.8268 inch) 34.500 - 34.750 mm (1.3583 - 1.3681 inch)
^ From Front Face 21.00 - 53.00 mm (0.8268 - 2.0866 inch) 34.892 - 34.912 mm (1.3737 - 1.3745 inch)
^ From Front Face 53.00 to Rolled Fillet (2.0866-Rolled Fillet) 33.450 - 33.550 mm (1.3169 - 1.3209 inch)
^ From Front Face 89.94 - 110.54 mm (3.5409 - 4.3520 inch) 44.950 - 45.000 mm (1.7697 - 1.7717 inch)
^ Crankshaft Nose Runout
^ From Front Face 0.00 - 21.00 mm (0.0000 - 0.8268 inch) 0.100 mm (0.0039 inch)
^ From Front Face 21.00 - 53.00 mm (0.8268 - 2.8066 inch) 0.030 mm (0.0012 inch)
^ From Front Face 53.00 to Rolled Fillet (2.0866-Rolled Fillet) 0.100 mm (0.0039 inch)
^ From Front Face 89.94 - 110.54 mm (3.5409 - 4.3520 inch) 0.025 mm (0.0010 inch)
^ Crankshaft Rear Flange
^ Diameter 95.880 - 95.980 mm (3.7748 - 3.7787 inch)
^ Runout 0.025 mm (0.0010 inch)
^ Crankshaft Rear Flange Face to Engine Flywheel Runout 0.025 mm (0.0010 inch)
^ Crankshaft Runout
^ Main Journals #1, #5 0.022 mm (0.0009 inch)
^ Main Journals #2, #4, #6 0.025 mm (0.0010 inch)
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.23 - 0.44 mm (0.009 - 0.017 inch)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.23 - 0.5 mm (0.009 - 0.0196 inch)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.44 - 0.7 mm (0.017 - 0.027 inch)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.44 - 0.76 mm (0.0173 - 0.03 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.18 - 0.75 mm (0.007 - 0.029 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.18 - 0.81 mm (0.007 - 0.032 inch)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.04 - 0.085 mm (0.00157 - 0.00335 inch)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.04 - 0.085 mm (0.00157 - 0.00335 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.04 - 0.078 mm (0.00157 - 0.0031 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.04 - 0.078 mm (0.00157 - 0.0031 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.012 - 0.2 mm (0.0005 - 0.0078 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.012 - 0.2 mm (0.0005 - 0.0078 inch)
Pistons and Pins
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.002 - 0.01 mm (0.00008 - 0.0004 inch)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.002 - 0.015 mm (0.00008 - 0.0006 inch)
Pin - Piston Pin Diameter 23.952 - 23.955 mm (0.943 - 0.943 inch)
Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.007 - 0.02 mm (0.00027 - 0.00078 inch)
Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.007 - 0.022 mm (0.00027 - 0.00086 inch)
Piston - Piston Diameter - Measured Over Skirt Coating 96.002 - 96.036 mm (3.779 - 3.78 inch)
Piston - Piston to Bore Clearance - Production -0.036 to +0.016 mm (-0.0014 to +0.0006 inch)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.071 mm (0.0028 inch)