System Specifications
Cylinder BlockHead gasket surface flatness
0.10 mm (0.004 inch) across the total area
0.05 mm (0.002 inch) across any 150 mm x 150 mm (6 inch x 6 inch) area
0.025 mm (0.001 inch) across any 25 mm x 25 mm (1 inch x 1 inch) area
Cylinder Bore
Diameter 94.999 - 95.001 mm (3.7401 - 3.7402 inch)
Maximum taper 0.076 mm (0.003 inch)
Maximum out-of-round 0.05 mm (0.002 inch)
Main bearing bore inside diameter 85.99 - 86.01 mm (3.3854 - 3.3862 inch)
Piston
Piston diameter
Standard size 94.9460 - 94.9186 mm (3.737 - 3.738 inch)
0.254 mm (0.010 inch) oversize 95.1738 - 95.1992 mm (3.747 - 3.748 inch)
0.508 mm (0.020 inch) oversize 95.4278 - 95.4532 mm (3.757 - 3.758 inch)
0.762 mm (0.030 inch) oversize 95.6818 - 95.7072 mm (3.767 - 3.768 inch)
Piston-to-cylinder bore clearance 0.0441 - 0.0909 mm (0.0017 - 0.0036 inch)
Ring end gap
Keystone 0.29 - 0.55 mm (0.011 - 0.021 inch)
Intermediate compression 1.40 - 1.66 mm (0.055 - 0.065 inch)
Oil control 0.24 - 0.50 mm (0.009 - 0.019 inch)
Ring groove width (measured over 2.08 mm (0.082 inch) gauge pins)
Upper limit 94.469 mm (3.719 inch)
Replacement limit 94.290 mm (3.712 inch)
Pin diameter 33.9975 - 34.0025 mm (1.3385 - 1.3387 inch)
Pin length 65.073 - 65.327 mm (2.5619 - 2.5719 inch)
Pin-to-piston fit 0.013 - 0.022 mm (0.0005 - 0.0009 inch)
Connecting Rod
Length (center to center) 176 mm (6.929 inch)
Bearing bore diameter 72.987 - 73.013 mm (2.8735 - 2.8745 inch)
Bearing-to-crankshaft clearance 0.0203 - 0.0837 mm (0.0008 - 0.0033 inch)
Side clearance 0.3 - 0.6 mm (0.012 - 0.024 inch)
Crankshaft
Main bearing journal diameter
Standard size 80.9873 - 81.0127 mm (3.188 - 3.150 inch)
0.254 mm (0.010 inch) undersize 80.7333 - 80.7587 mm (3.178-3.140 inch)
0.508 mm (0.020 inch) undersize 80.4793 - 80.5047 mm (3.168 - 3.130 inch)
0.762 mm (0.030 inch) undersize 80.2253 - 80.2507 mm (3.158 - 3.120 inch)
Journal-to-cylinder block clearance 0.020 - 0.086 mm (0.008 - 0.0034 inch)
Connecting rod journal diameter
Standard size 68.99 to 69.01 mm (2.716 to 2.717 inch)
0.254 mm (0.010 inch) undersize 68.73 to 68.75 mm (2.706 to 2.707 inch)
0.508 mm (0.020 inch) undersize 68.48 to 68.50 mm (2.696 to 2.697 inch)
0.762 mm (0.030 inch) undersize 68.23 to 68.25 mm (2.686 to 0.687 inch)
Crankshaft maximum end play 0.508 mm (0.020 inch)
Main Bearing Cap Fasteners
To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
Lower bolts
First pass 122 Nm (90 ft. lbs.)
Second pass 163 Nm (120 ft. lbs.)
Final pass 231 Nm (170 ft. lbs.)
Outer bolts 31 Nm (23 ft. lbs.)
Crankshaft Pulley Bolts
To prevent engine damage, you must always install 4 new bolts when installing the vibration damper.
Do not use anti-seize compounds, grease or any lubricants. Lubricants have an adverse effect on the torque results.
First pass 68 Nm (50 ft. lbs.)
Final pass tighten 90°