System Specifications

Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 in )
Cylinder bore maximum taper 0.050 mm (0.0()2 inch)
Cylinder bore maximum out-of-round 0.050 mm (0.()02 inch)
Main bearing bore inside diameter 68.905-68.885 mm (2.713-2.712 inch)
Head gasket surface flatness 0.08 mm (0.003 inch) in 152.0 mm (6.00 inch)
Head gasket surface finish (RMS) 2.0 @ 0.85.5 @ 2.5
Crankshaft
Main bearing journal diameter 1,2,3 63.983-64.003 mm (2.5190-2.5198 inch)
Main bearing journal maximum taper 0.008 mm (0.0003 inch) per 25 mm (1 inch)
Main bearing journal maximum out-of-round 0.0003 mm MAX in 45 degrees, 0.015 mm (0.006 inch) TOTAL
Main bearing journal-to-cylinder block clearance-desired 0.025-0.035 (0.001-0.0014 inch)
Main bearing journal-to-cylinder block clearance-allowable 0.013-0.058 mm (0.0005-0.0023 inch)
Connecting rod journal diameter 58.682-58.702 mm (2.3103-2.3111 inch)
Connecting rod journal maximum taper 0.008 mm per 25 mm (0.0003 in per inch)
Connecting rod journal maximum out-of-round 0.008 mm (0.0003 inch) MAX in 45 degrees. 0.015 mm (0.0006 in) TOTAL
Crankshaft maximum end play 0.20 mm (0.008 inch)
Piston b and Connecting Rod
Piston diameter-coded red 96.795-96.782 mm (3.81082-3.81031 inch)
Piston diameter-coded blue 96.808-96.795 mm (3.81133-3.81082 inch)
Piston diameter-coded yellow 96.821-96.808 mm (3.81184-3.81133 inch)
Piston-to-cylinder bore clearance (uncoated clearance) 0.018-0.044 mm (0.007-0.0017 inch)
Piston ring end gap- compression (top) (in gauge) 0.17-0.33 mm (0.0067-0.0130 inch)
Piston ring end gap -compression (bottom) (in gauge) 0.3-0.55 mm (0.0118-0.0217 inch)
Piston ring end gap-oil ring (steel rail) (in gauge) 0.15-0.65 mm (0.0059-0.0256 inch)
Piston ring groove width-compression (top) 1.54-1.52 mm (0.0606-0.0598 inch)
Piston ring groove width-compression (bottom) 1.54-1.52 mm (0.0606-0.0598 inch)
Piston ring groove width - oil 3.05-3.03 mm (0.1200-0.1193 inch)
Piston ring width-compression (top) 1.460-1.490 mm (0.0575-0.0587 inch)
Piston ring width- compression (bottom) 1.460-1.490mm (0.0575-0.0587 inch)
Piston ring width-oil ring side seal-snug fit
Piston ring-to-groove clearance-1st ring 0.030-0.080 mm (0.0012-0.0032 inch)
Piston ring-to-groove clearance-2nd ring 0.030-0.080 mm (0.0012-0.0032 inch)
Piston pin bore diameter 23.014-23.018 mm (0.9061-0.9062 inch)
Piston pin diameter 23.000-23.003 mm (0.9055-0.9056 inch)
Piston pin length 63.55-63.05 mm (2.5096-2.4823 inch)
Piston pin-to-piston fit 0.011-0.018 mm (0.0004-0.0007 inch)
Connecting rod-to-pin clearance press fit 8 kilo newtons (1 800 lbs)
Connecting rod pin bore diameter 21.5 mm (0.8465 inch)
Connecting rod length (center-to-center) 154.66-154.74 mm (6.08896-6.09211 inch)
Connecting rod maximum allowed bend 0.04 per 25 mm (0.0016 per inch)
Connecting rod maximum allowed twist 0.059 per 25 mm (0.002 per inch)
Connecting rod bearing bore diameter 61.635-61.655 mm (2.4266-2.4274 inch)
Connecting rod bearing-to-crankshaft clearance-desired 0.025-0.035 mm (0.001-0.0014 inch)
Connecting rod bearing-to-crankshaft clearance-allowable 0.022-0.069 mm (0.00086-0.0027 inch)
Connecting rod side clearance-standard 0.11 -0.49 mm (0.0047-0.0193 inch)
Connecting rod side clearance-service limit 0.36 mm MAX (0.014 in MAX)
Balance Shaft
Journal diameter 52.108-52.082 mm (2.0515-2.0505 inch)
Bore inside diameter 55.689-55.664 mm (2.192-2.191 inch)
Maximum runout 0.025 mm (0.001 inch)
End play 0.075-0.200 mm (0.003-0.008 inch)

a Time required for the plunger to leak down 1.6 mm of travel with 222 N force and leak-down fluid in the lash adjuster.
b When installing new pistons. measure the cylinder bore. Install the service piston matched to the piston bore diameter above.

Crankshaft pulley bolt 160 Nm (118 ft. lbs.)
For specifications regarding Main Bearing Cap bolts, refer to service procedure. Assembly
For specifications regarding Rod Bearing Cap bolts, refer to service procedure. Assembly