Cylinder Block Assembly: Specifications
Cylinder bore diameter - grade 1 90.200-90.213 mm (3.5512-3.5517 in)Cylinder bore diameter - grade 2 90.213-90.226 mm (3.5517-3.5522 in)
Cylinder bore diameter - grade 3 90.226-90.239 mm (3.5522-3.5527 in)
Cylinder bore maximum taper 0.006 mm (0.00023 in)
Cylinder bore maximum out-of-round 0.020 mm (0.00079 in)
Cylinder bore diameter-surface finish (RMS) 0.2-0.6 microns
Piston-to-cylinder bore clearance 0.012-0.0026 mm (0.0005-0.0001 in)
Main bearing journal diameter 67.483-67.503 mm (2.65 in)
Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-round 0.06 mm (0.002 in)
Main bearing journal-to- cylinder block clearance 0.027-0.065 mm (0.00 11-0.0026 in)
Crankshaft maximum end play 0.130-0.301 mm (0.0051-0.012 in)
Main Bearing Cap
Tighten the vertical main bearing cap fasteners in 2 stages:
Stage 1 40 Nm (30 ft. lbs.)
Stage 2 Tighten an additional 90 degrees
Tighten the jack screws against the cylinder block in the sequence shown:
^ Tighten to 5 Nm (44 in lbs)
^ Tighten to 10 Nm (89 in lbs)
Install the side bolts and tighten in the sequence shown:
^ Tighten to 21 Nm (15 ft lbs)
Connecting rod side clearance (assembled to crank) - standard 0.015-0.45 mm (0.0006-0.0177 in)
Connecting rod side clearance (assembled to crank) - service limit 0.05 mm (0.002 in) max.
Connecting rod bearing bore diameter 56.756-56.876 mm (2.234-2.24 in)
Connecting rod bearing-to-crankshaft clearance 0.027-0.069 mm (0.001-0.0027 in)
Connecting rod-to-pin clearance 0.015-0.040 mm (0.0006-0.0016 in)
Piston diameter - coded red 1 90.177-90.197 mm
(3.550-3.551 in)
Piston diameter - coded blue 2 90.190-90.210 mm
(3.5507-3.5515 in)
Piston diameter - coded yellow 3 90.203-90.223 mm
(3.513-3.5521 in)
Piston ring end gap - compression (top and bottom) 0.23-0.49 mm (0.010-0.020 in)
Piston ring end gap - oil ring (steel rail) 0.05-0.66 mm (0.006-0.026 in)
Piston ring groove width - compression (top) 1.520-1.550 mm (0.002-0.610 in)
Piston ring groove width - compression (bottom) 1.520-1.530 mm (0.060-0.0602 in)
Piston ring groove width - oil ring 6,996-7,224 mm (0.275-0.2844 in)
Piston ring width - compression 1.49-1.47 mm
(0.0587-0.0579 in)
Piston ring width - oil ring rail (2) 0.473-0.447 mm (0.0186-0.0176 in), 0.483 mm (0.0190 in) max. at ID
Piston ring width - oil ring expander 2.038-1.960 mm
(0.080-0.077 in)
Piston ring-to-groove clearance - compression 0.030-0.070 mm
(0.0012-0.0028 in)
Piston ring-to-groove clearance - oil ring assembly 0.046-0.196 mm (0.0018-0.0077 in)
Piston pin bore diameter 22.0015-22.004 mm (0.866-0.8663 in)
Piston pin diameter 22.0 mm (0.866 in)
Piston pin length 61.8 mm (2.433 in)
Piston pin-to-piston fit 0.005-0.010 mm (0.0002-0.0004 in)
Crankshaft Pulley
Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
Stage 1 90 Nm (66 ft. lbs.)
Stage 2 Loosen the bolt one full turn.
Stage 3 50 Nm (37 ft. lbs.)
Stage 4 Tighten the bolt an additional 90 degrees without exceeding 200 Nm (148 ft. lbs.)