System Specifications
Cylinder BlockCylinder bore
Diameter
Grade 1 90.200-90.210 mm (3.5512-3.5516 inch)
Grade 2 90.210-90.220 mm (3.5516-3.5520 inch)
Grade 3 90.220-90.230 mm (3.5520-3.5524 inch)
Maximum taper 0.006 mm (0.0002 inch)
Maximum out-of-round 0.020 mm (0.0008 inch)
Main bearing bore inside diameter 72.400-72.424 mm (2.850-2.851 inch)
Crankshaft
Main bearing journal
Diameter 67.481-67.505 mm (2.6567-2.6576 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round 0.0075 mm (0.0003 inch) between cross sections
Journal-to-cylinder block clearance 0.048-0.024 mm (0.0019-0.0009 inch)
Connecting rod journal
Diameter 53.003-52.983 mm (2.0867-2.0859 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round 0.0075 mm (0.0003 inch) between cross sections
Crankshaft maximum end play 0.075-0.377 mm (0.0030-0.0148 inch)
Piston
Diameter (at right angle to pin bore)
Grade 1 90.175-90.165 mm (3.5502-3.5498 inch)
Grade 2 90.185-90.175 mm (3.5506-3.5502 inch)
Grade 3 90.195-90.185 mm (3.5510-3.5506 inch)
Piston-to-cylinder bore clearance (at grade size) 0.025-0.045 mm (0.0010-0.0018 inch)
Ring end gap
Top 0.15-0.30 mm (0.006-0.012 inch)
Intermediate 0.25-0.50 mm (0.0098-0.0197 inch)
Oil control 0.15-0.65 mm (0.0059-0.0256 inch)
Ring groove width
Top 1.52-1.55 mm (0.0598-0.0610 inch)
Intermediate 1.52-1.54 mm (0.0598-0.0606 inch)
Oil control 3.030-3.050 mm (0.1193-0.1201 inch)
Ring width - top and intermediate 1.50-1.47 mm (0.0590-0.0578 inch)
Ring-to-groove clearance
Top 0.020-0.080 mm (0.0008-0.0031 inch)
Intermediate 0.030-0.070 mm (0.0012-0.0028 inch)
Pin
Bore diameter 22.008-22.014 mm (0.8665-0.8667 inch)
Pin diameter 22.0010-22.0030 mm (0.8662-0.8663 inch)
Length 61.8 mm (2.433 inch)
Pin-to-piston fit 0.005-0.013 mm (0.0002-0.0005 inch)
Connecting Rod
Rod-to-pin clearance 0.009-0.0235 mm (0.0004-0.0093 inch)
Pin bore diameter 22.012-22.024 mm (0.8666-0.8671 inch)
Length (center-to-center) 169.1 mm (6.6575 inch)
Maximum allowed bend ± 0.038 mm (0.0015 inch)
Maximum allowed twist(a) ± 0.05 mm (0.0020 inch)
Rod bearing
Bore diameter (with assembled liners) 53.049-53.027 mm)(2.0885-2.0877 inch)
Bearing-to-crankshaft clearance 0.064-0.026 mm (0.0025-0.0010 inch)
Rod side clearance 0.475-0.125 mm (0.0187-0.0049 inch)
(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.
Main Bearing Size Codes
Vertical Main Bearing Cap Fasteners
First pass 40 Nm (30 ft. lbs).
Final pass Tighten 90°
Side Bolts
First pass 30 Nm (22 ft. lbs).
Final pass Tighten 90°
Crankshaft Pulley Bolt
Discard the crankshaft pulley bolt.
First pass 90 Nm (66 ft. lbs.)
Second pass Loosen 360°
Third pass 50 Nm (37 ft. lbs.)
Final pass Tighten 90°