Cylinder Block Assembly: Specifications
SURFACE VARIATIONFlatness Of The Separating Surface Of The Cylinder Head 0.05 mm (0.002 in.)
CYLINDER BLOCK
Cylinder Liner Diameter
Standard dimensions 83.009 mm (3.268 in)
Group code letter A 83.000 - 83.006 mm (3.2678 - 3.268 in.)
Group code letter X 83.006 - 83.012 mm (3.268 - 3.2682 in.)
Group code letter B 83.012 - 83.018 mm (3.2682 - 3.2685 in.)
Cylinder Liner
Wear limit in longitudinal and transverse direction 0.20 mm (0.0079 in.)
Permissible difference for cylinder shape (when new) 0.000 - 0.007 mm (0.000 -0.0003 in.)
Wear limit 0.05 mm (0.0002 in.)
Permissible difference for rectangularity related to cylinder height 0.05 mm (0.0002 in.)
Basic peak-to-valley height (R3Z) 0.002 - 0.005 mm (0.0001 -0.0002 in.)
Maximum peak-to-valley height (Rmax) 0.011 mm (0.0005 in.)
Honing angle 40 - 60° (40 - 60°)
CRANKSHAFT
Crankshaft Journal Diameter
Nominal Diameter 75.940 - 75.965 mm (2.98 -2.99 in.)
First Repair Size 75.960 - 75.965 mm (2.9906 -2.9908 in.)
Second Repair Size 75.955 - 75.960 mm (2.9904 -2.9906 in.)
Third Repair Size 75.950 - 75.955 mm (2.9902 -2.9904 in.)
Fourth Repair Size 75.945 - 75.950 mm (2.99 -2.9902 in.)
Fifth Repair Size 75.940 - 75.945 mm (2.9898 -2.99 in.)
Crankshaft Journal Width At Fit Bearing
Identification Colorless/0 29.500 - 29.533 mm (1.16 -1.163 in.)
Red/1 29.600 - 29.633 mm (1.164 -1.166 in.)
Standard Dimension For Main Bearing Shells In Crankcase Upper And Lower Sections - Diameter 70.00 mm (2.755 in.)
Bearing shell thickness (Replacement part additional number (color coding blue) - 52) 2.250 - 2.255 mm (0.0886 -0.0876 in.)
Bearing shell thickness (Replacement part additional number (color coding yellow) - 54) 2.255 - 2.260 mm (0.0876 -0.089 in.)
Bearing shell thickness (Replacement part additional number (color coding red) - 56) 2.260 - 2.265 mm (0.089 -0.0892 in.)
Bearing shell thickness (Replacement part additional number (color coding white) - 57) 2.265 - 2.270 mm (0.089 -0.0894 in.)
Bearing shell thickness (Replacement part additional number (color coding purple) - 58) 2.270 - 2.275 mm (0.0894 -0.0896 in.)
Crankshaft Bearing Clearance (When New) 0.029 - 0.056 mm (0.0012 - 0.0023 in.)
Axial play of crankshaft 0.100 - 0.254 mm (0.004 -0.01 in.)
Crankshaft Main Bearing Cap Bolts
Thread Diameter 11 mm (0.43 in.)
Length When New 66 mm (2.5985 in.)
Maximum Length 67.8 mm (2.6693 in.)
MAIN BEARING
Crankshaft Journal Diameter
Nominal Diameter 75.940 - 75.965 mm (2.98 -2.99 in.)
First Repair Size 75.960 - 75.965 mm (2.9906 -2.9908 in.)
Second Repair Size 75.955 - 75.960 mm (2.9904 -2.9906 in.)
Third Repair Size 75.950 - 75.955 mm (2.9902 -2.9904 in.)
Fourth Repair Size 75.945 - 75.950 mm (2.99 -2.9902 in.)
Fifth Repair Size 75.940 - 75.945 mm (2.9898 -2.99 in.)
Crankshaft Journal Width At Fit Bearing
Identification Colorless/0 29.500 - 29.533 mm (1.16 -1.163 in.)
Red/1 29.600 - 29.633 mm (1.164 -1.166 in.)
Standard Dimension For Main Bearing Shells In Crankcase Upper And Lower Sections - Diameter 70.00 mm (2.755 in.)
Bearing shell thickness (Replacement part additional number (color coding blue) - 52) 2.250 - 2.255 mm (0.0886 -0.0876 in.)
Bearing shell thickness (Replacement part additional number (color coding yellow) - 54) 2.255 - 2.260 mm (0.0876 -0.089 in.)
Bearing shell thickness (Replacement part additional number (color coding red) - 56) 2.260 - 2.265 mm (0.089 -0.0892 in.)
Bearing shell thickness (Replacement part additional number (color coding white) - 57) 2.265 - 2.270 mm (0.089 -0.0894 in.)
Bearing shell thickness (Replacement part additional number (color coding purple) - 58) 2.270 - 2.275 mm (0.0894 -0.0896 in.)
Crankshaft Bearing Clearance (When New) 0.029 - 0.056 mm (0.0012 - 0.0023 in.)
MAIN BEARING CAP
Bolt, crankshaft bearing cap to crankshaft bearing body
Stage 1 35 Nm (309 in.lbs)
Stage 2 95 Degrees
Stage 3 95 Degrees
Lateral bolt, crankcase to crankcase bearing cap
Stage 1 53 Nm (309 in.lbs)
Stage 2 95 Degrees
CONNECTING RODS
Distance From Center Of Connecting Rod Bearing Bore To Connecting Rod Bushing Bore 167.97 - 168.03 mm (6.613 -6.6154 in.)
Width Of Connecting Rod At Connecting Rod Bearing Bore 17.90 - 18.10 mm (0.7048 -0.7126 in.)
Width Of Connecting Rod At Connecting Rod Bushing Bore 21.94 - 22.00 mm (0.8638 -0.8662 in.)
Connecting Rod Bushing Inner 30.038 - 30.044 mm (1.1826 -1.1829 in.)
Connecting Rod Bushing Outer Diameter 32.500 - 32.525 mm (1.2796 -1.2806 in.)
Piston Pin Play In Connecting Rod Bushing 0.028 - 0.034 mm (0.0012 -0.0014 in.)
Peak-To-Valley Height (Rz) Of Connecting Rod Bushing On Inside 5 mm (0.1969 in.)
Connecting Rod Bearing Shell Basic Bore 67.600 - 67.614 mm (2.6615 -2.662 in.)
Permissible Out-Of-Roundness And Concentricity Of Basic Bore 0.020 mm (0.0008 in.)
Permissible Twist Of Connecting Rod Bearing Bore To Connecting Rod Bush Bore Over A Length Of 100 mm 0.1 mm (0.004 in.)
Permissible Variation Of Axial Parallelism Of Connecting rod Bearing Bore To Connecting rod Bushing Bore Over A Length Of 100 mm 0.045 mm (0.0018 in.)
Permissible Difference In Weight Of Complete Connecting Rod Of An Engine 2 grams (0.07 oz.)
Connecting Rod Bolt
Thread diameter 8 mm (0.315 in.)
Shank length when new 47 mm (1.8504 in.)
Maximum shank length 48 mm (1.8898 in.)
PISTONS
Piston Diameter
Piston group A 82.833 - 82.839 mm (3.2612 -3.2614 in.)
Piston group X 82.838 - 82.846 mm (3.2614 -3.2617 in.)
Piston group B 82.845 - 82.851 mm (3.2617 -3.2619 in.)
1st repair size (Piston group +5) 82.876 - 82.890 mm (3.2629 -3.2634 in.)
2nd repair size (Piston group +10) 82.926 - 82.940 mm (3.2648 -3.2654 in.)
PISTON RINGS
Piston Ring End Clearance
Groove 1 0.12 - 0.16 mm (0.0048 -0.0063 in.)
Groove 2 0.065 - 0.110 mm (0.0026 -0.0044 in.)
Groove 3 0.03 - 0.07 mm (0.0012 -0.0028 in.)
CRANKSHAFT PULLEY
Vibration Damper - Bolt 210 Nm plus 180 degrees (154 ft. lbs. plus 180 degrees)