System Specifications

Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 inch)
Cylinder bore maximum taper 0.050 mm (0.002 inch)
Cylinder bore maximum out-of-round - limit 0.025 mm (0.001 inch)
Cylinder bore maximum out-of-round - service limit 0.050 mm (0.002 inch)
Main bearing bore inside diameter 68.905-68.885 mm (2.713-2.712 inch)
Camshaft bearing bore inside diameter - No. 1 55.689-55.664 mm (2.192-2.191 inch)
Camshaft bearing bore inside diameter - No. 2 and No. 3 55.308-55.283 mm (2.177-2.176 inch)
Camshaft bearing bore inside diameter - No. 4 55.684-55.664 mm (2.192-2.191 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 0.008 mm (0.0003 inch) maximum in 45 degrees, 0.015 mm (0.0006 inch) total
Main bearing journal-to-cylinder block clearance - desired 0.025-0.035 mm (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 -
Connecting rod journal maximum taper -
Connecting rod journal maximum out-of-round -
Crankshaft maximum end play 0.10-0.20 mm (0.004-0.008 inch)
Thrust bearing journal diameter 58.682-58.702 mm (2.3103-2.3111 inch)
Thrust bearing journal maximum out-of-round 0.008 mm (0.0003 inch) maximum in 45 degrees, 0.015 mm (0.0006 inch) total
Thrust bearing journal maximum taper - limit 0.008 mm per 25 mm (0.0003 in per inch)
Thrust bearing journal maximum taper - service limit 0.3 microns (11.8 micro inch)
Thrust bearing journal length 29.725-29.775 mm (1.703-1.722 inch)

Main bearing cap bolts
Tighten the bearing cap bolts in 2 stages.
Stage 1 55 Nm (41 ft. lbs.)
Stage 2 additional 90 degrees

Piston and Connecting Rod
Piston diameter - coded red 96.795-96.782 mm (3.8108-3.8103 inch)
Piston diameter - coded blue 96.808-96.795 mm (3.8113-3.8108 inch)
Piston diameter - coded yellow 96.821-96.808 mm (3.8119-3.8113 inch)
Piston-to-cylinder bore clearance (uncoated clearance) 0.018-0.044 mm (0.0007-0.0017 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 (0.006-0.026 inch)
Piston ring groove width - compression (top and bottom) 1.54-1.52 mm (0.0606-0.0598 inch)
Piston ring groove width - oil 3.05-3.03 mm (0.1201-0.1193 inch)
Piston ring width - compression (top and bottom) 1.460-1.490 mm (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 (2.5020-2.4823 inch)
Piston pin-to-piston fit 0.011-0.018 mm (0.0004-0.0007 inch)
Piston-to-connecting rod clearance Press fit 8 kilonewtons (1,800 lbs.)
Connecting rod-to-pin clearance -
Connecting rod pin bore diameter 22.94-22.98 mm (0.9032-0.9047 inch)
Connecting rod length (center-to-center) 154.66-154.74 mm (6.0890-6.0921 inch)
Connecting rod maximum allowable bend 0.04 per 25 mm (0.0016 in per inch)
Connecting rod maximum allowable twist 0.059 per 25 mm (0.002 in 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 (0.0009-0.0027 inch)
Connecting rod side clearance (assembled to crank) - standard 0.11-0.49 mm (0.0043-0.0193 inch)
Connecting rod side maximum clearance (assembled to crank) - service limit 0.36 mm (0.014 inch)

Crankshaft pulley bolt 160 Nm (118 ft. lbs.)