Cylinder Block Assembly: Specifications
Cylinder BlockCylinder bore diameter grade 1 - 90.200-90.210 mm (3.5512-3.5516 in)
Cylinder bore diameter grade 2 - 90.210-90.220 mm (3.5516-3.5520 in)
Cylinder bore diameter grade 3 - 0.220-90.230 mm (3.5520-3.5524 in)
Cylinder bore maximum taper 0.006 mm (0.0002 in)
Cylinder bore maximum out-of-round 0.020 mm (0.0008 in)
Main bearing bore inside diameter 72.401-72.422 mm (2.850-2.851 in)
Crankshaft
Main bearing journal diameter 67.481-67.505 mm (2.6568-2.6576 in)
Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-round 0.0075 mm (0.0003 in) between cross sections
Main bearing journal-to-cylinder block clearance 0.048-0.024 mm (0.0019-0.0009 in)
Connecting rod journal diameter 53.003-52.983 mm (2.0867-2.0859 in)
Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-round 0.0075 mm (0.0003 in) between cross sections
Crankshaft maximum end play 0.075-0.377 mm (0.0030-0.0148 in)
Piston and Connecting Rod
Piston diameter - grade 1 (at right angle to pin bore) 90.175-90.165 mm (3.5502-3.5498 in)
Piston diameter - grade 2 (at right angle to pin bore) 90.185-90.175 mm (3.5506-3.5502 in)
Piston diameter - grade 3 (at right angle to pin bore) 90.195-90.185 mm (3.5510-3.5506 in)
Piston-to- cylinder bore clearance (at grade size) 0.025-0.045 mm (0.0010-0.0018 in)
Piston ring end gap - top 0.13-0.28 mm (0.0051-0.0110 in)
Piston ring end gap - intermediate 0.25-0.40 mm (0.0098-0.0158 in)
Piston ring end gap - oil control 0.15-0.65 mm (0.0059-0.0256 in)
Piston ring groove width - top 1.53-1.55 mm (0.0602-0.0610 in)
Piston ring groove width - intermediate 1.52-1.54 mm (0.0598-0.0606 in)
Piston ring groove width - oil control 3.030-3.050 mm (0.1193-0.1201 in)
Piston ring width 1.49-1.46 mm (0.0587-0.0575 in)
Piston ring-to-groove clearance - top 0.030-0.050 mm (0.0012-0.0020 in)
Piston ring-to-groove clearance - intermediate 0.030-0.080 mm (0.0012-0.0031 in)
Piston pin bore diameter 22.008-22.014 mm (0.8665-0.8667 in)
Piston pin diameter 22.0005-22.0030 mm (0,8662-0,8663 in)
Piston pin length 61.8 mm (2.433 in)
Piston pin-to-piston fit 0.005-0.0135 mm (0.0002-0.0005 in)
Connecting rod-to-pin clearance 0.009-0.0235 mm (0.0004-0.0093 in)
Connecting rod pin bore diameter 22.012-22.024 mm (0.8666-0.8671 in)
Connecting rod length (center-to-center) 169.1 mm (6.6575 in)
Connecting rod maximum allowed bend 0.038 mm (0.0015 in)
Connecting rod maximum allowed twist a 0.05 mm (0.0020 in)
Connecting rod bearing bore diameter (with assembled liners) 53.049-53.027 mm (2.0885-2.0877 in)
Connecting rod bearing-to-crankshaft clearance 0.064-0.026 mm (0.0025-0.0010 in)
Connecting rod side clearance 0.475-0.125 mm (0.0187-0.0049 in)
Balance Shaft System
Balance shaft journal diameter 26.962 - 26.936 mm
Clearance - balance shaft journal-to-cylinder head 0.076 - 0.025 mm
Cylinder head balance shaft journal diameter 27.012 - 26.987 mm
Gear backlash 0.0076 - 0.1295 mm
Balance shaft end play 0.04 - 0.18 mm
Rod length (centerline bore-to-bore) 169.1 mm
Alignment
Bore-to-bore max. twist ± 0.05 mm
Bore-to-bore max. bend ± 0.038 mm
Side play (as assembled to crank)
Standard play 0.410 ± 0.26 mm
Max. play 0.670 mm
Surface Variation
Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61 cm (24 inch) long, the machined edge must be flat with 0.010 mm (0.0004 inch) from end to end.
a The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline.
Crankshaft Lower Main Bearings
Install the 10 dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
Tighten fasteners 1 through 12 in 2 stages, in the sequence shown.
Stage 1: Tighten to 40 Nm (30 ft. lbs.).
Stage 2: Tighten an additional 90 degrees.
Tighten fasteners 13 through 24 in 2 stages, in the sequence shown.
Stage 1: Tighten to 30 Nm (22 ft. lbs.).
Stage 2: Tighten an additional 90 degrees.
NOTE: Install the balance shaft bearing caps in their original locations.
Balance Shaft Bearing caps
Install the bolts and tighten in the sequence shown.
Tighten to 10 Nm (89 inch lbs.).
Connecting Rod
NOTE: Be sure to tighten the bolts in two stages.
Tighten the connecting rod bolts in the sequence shown.
Stage 1: Tighten to 43 Nm (32 ft. lbs.).
Stage 2: Tighten an additional 105 degrees.
Crankshaft Pulley
Tighten the bolt in 4 stages.
Stage 1: Tighten to 90 Nm (66 ft. lbs.).
Stage 2: Loosen 360 degrees.
Stage 3: Tighten to 50 Nm (37 ft. lbs.).
Stage 4: Tighten an additional 90 degrees.