Cylinder Block Assembly: Specifications
GENERAL SPECIFICATIONSMax. Variation Between Cylinders 25%
Displacement 2.4 Liters 148 cu. in.
Bore 87.5 mm 3.445 in.
Stroke 101.0 mm 3.976 in.
Compression Pressure 1172-1551 kPa (170-225 psi)
CYLINDER BLOCK
Cylinder Bore Diameter 87.4924-87.5076 mm 3.4446-3.4452 in.
Out-of-Round (Max.) 0.051 mm 0.002 in.
Taper (Max.) 0.051 mm 0.002 in.
PISTONS
Piston Diameter
Non-Turbo 87.456-87.474 mm 3.4431-3.4439 in.
Turbo 87.436-87.454 mm 3.4424-3.4431 in.
Clearance @ 24.6 mm (0.551 inch) from bottom of skirt (Non-Turbo) 0.018-0-0516 mm 0.0007-0.0020 in.
Clearance @ 22 mm (0.866 inch) from bottom of skirt (Turbo) 0.046-0.064 mm 0.0018-0.0025 in.
Weight
Non-Turbo 345-355 grams (12.17-12.52 oz.)
Turbo 331-339 grams (11.67-11.95 oz.)
Land Clearance (Diametrical)
Non-Turbo 0.563-0.621 mm 0.022-0.024 in.
Turbo 0.556-0.674 mm 0.021-0.027 in.
Piston Length
Non-Turbo 66.25 mm 2.608 in.
Turbo 61.43 mm 2.419 in.
Piston Ring Groove Depth No. 1
Non-Turbo 3.946-4.045 mm 0.155-0.159 in.
Turbo 3.713-3.882 mm 0.146-0.153 in.
Piston Ring Groove Depth No. 2
Non-Turbo 4.555-4.680 mm 0.179-0.184 in.
Turbo 4.118-4.297 mm 0.162-0.169 in.
Piston Ring Groove Depth No. 3
Non-Turbo 4.108-4.220 mm 0.162-0.166 in.
Turbo 2.818-2.967 mm 0.110-0.116 in.
PISTON RINGS
Ring Gap-Top Compression Ring
Non-Turbo 0.25-0.51 mm 0.0098-0.020 in.
Turbo 0.20-0.40 mm 0.0078-0.0157 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-2nd Compression Ring
Non-Turbo 0.23-0.48 mm 0.009-0.018 in.
Turbo 0.20-0.40 mm 0.007-0.015 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-Oil Control Steel Rails
Non-Turbo 0.25-0.64 mm 0.009-0.025 in.
Turbo 0.15-0.66 mm 0.005-0.025 in.
Wear Limit 1.0 mm 0.039 in.
Ring Side Clearance Compression Rings
Non-Turbo 0.030-0.080 mm 0.0011-0.0031 in.
Turbo 0.035-0.085 mm 0.001-0.003 in.
Wear Limit 0.10 mm 0.004 in.
Ring Side Clearance-Oil Ring Pack
Non-Turbo 0.012-0.178 mm 0.0004-0.0070 in.
Turbo 0.027-0.176 mm 0.001-0.006 in.
Ring Width Compression Rings
Non-Turbo 1.47-1.50 mm 0.057-0.059 in.
Turbo Top Ring 1.17-1.19 mm 0.0460-0.0468 in.
Turbo 2nd Ring 1.472-1.49 mm 0.057-0.058 in.
Ring Width-Oil Ring Pack
Non-Turbo 2.72-2.88 mm 0.107-0.1133 in.
Turbo 2.64-2.89 mm 0.103-0.113 in.
CONNECTING ROD
Bearing Clearance 0.025-0.071 mm 0.0009-0.0027 in.
Wear Limit 0.075 mm 0.003 in.
Bore Diameter Piston Pin
Non-Turbo 20.96-20.98 mm 0.8252-0.8260 in.
Turbo 22.007-22.015 mm 0.8664-0.8667 in.
Bore Diameter Crankshaft End
Non-Turbo 52.993-53.007 mm 2.0863-2.0868 in.
Turbo 52.992-53.008 mm 2.0862-2.0869 in.
Side Clearance 0.13-0.38 mm 0.005-0.015 in.
Wear Limit 0.40 mm 0.016 in.
Weight-Total (Less Bearing)
Non-Turbo 565.8 grams 19.96 oz.
Turbo 663.5 grams 23.4 oz.
CRANKSHAFT
Connecting Rod Journal Diameter 49.984 - 50.000 mm 1.968 - 1.9685 in.
Main Bearing Journal Diameter 59.992 - 60.008 mm 2.362 - 2.3625 in.
Journal Out-of-Round (Max.) 0.0035 mm 0.0003 in.
Journal Taper (Max.) 0.007 mm 0.0001 in.
End Play 0.09 - 0.24 mm 0.0035 - 0.0094 in.
Wear Limit 0.38 mm 0.015 in.
Main Bearing Diametrical Clearance 0.018 - 0.062 mm 0.0007 - 0.0024 in.
TORQUE
Balance Shaft Carrier to Block-Bolts 54 Nm (40 ft. lbs.)
Balance Shaft Gear Cover
Double Ended Fastener 12 Nm (105 inch lbs.)
Balance Shaft Sprocket-Bolt 28 Nm (250 inch lbs.)
Balance Shaft Chain Tensioner-Bolts 12 Nm (105 inch lbs.)
Balance Shaft Carrier Cover-Bolts 12 Nm (105 inch lbs.)
Connecting Rod Cap-Bolts 27 +1/4 turn 20 +1/4 turn
Crankshaft Damper-Bolt 136 Nm (100 ft. lbs.)
Crankshaft Main Bearing Cap/Bedplate
M8 Bolts 28 Nm (250 inch lbs.)
M11 Bolts 75 Nm (55 ft. lbs.)
Install Main bearing cap/bed plate to engine block bolts
Install 11, 17, and 20 finger tight.
Tighten these bolts down together until the bed plate contacts the cylinder block (Fig. 68).
Install and tighten bolts (1-10) in sequence shown in (Fig. 68)
Tighten to 41 Nm (30 ft. lbs.).
Tighten bolts (1-10) again to 41 Nm (30 ft. lbs.)
in sequence shown in (Fig. 68).
Install main bearing bed plate to engine block bolts (11-20)
Torque each bolt to 28 Nm (250 inch lbs.)
in sequence shown in (Fig. 68).
Tighten bolts (1-10) to 75 Nm (55 ft. lbs.)
in sequence shown in (Fig. 68).
Tighten bolts (11-20) again to 28 Nm (250 inch lbs.)
in sequence shown in (Fig. 68).
Connecting Rod Cap-Bolts 27 +1/4 turn 20 +1/4 turn