System Specifications
Cylinder BlockCylinder bore diameter grade 1 89.000 - 89.010 mm (3.503 - 3.504 inch)
Cylinder bore diameter grade 2 89.010 - 89.020 mm (3.504 inch)
Cylinder bore diameter grade 3 89.020 - 89.030 mm (3.504 - 3.505 inch)
Cylinder bore maximum taper 0.020 mm (0.0007 inch)
Cylinder bore maximum out of round limit 0.015 mm (0.0005 inch)
Cylinder bore maximum out of round service limit 0.020 mm (0.0007 inch)
Main bearing bore inside diameter 67.998 - 68.022 mm (2.677 - 2.6780 inch)
Head gasket surface flatness 0.025 - 0.050 mm (0.0009 - 0.0019 inch)
Head gasket surface finish 0.12 mm (0.004 inch)
Crankshaft Main bearing journal diameter 62.968 - 62.992 mm (2.479 - 2.480 inch)
Main bearing journal maximum taper
Main bearing journal maximum out of round
Main bearing journal to cylinder block clearance
Connecting rod journal diameter 49.970 - 49.990 mm (1.967 - 1.968 inch)
Connecting rod journal maximum taper
Connecting rod journal maximum out of round
Crankshaft maximum end play 0.110 - 0.232 mm (0.004 inch)
Piston and Connecting Rod
Piston diameter coded grade 1 88.990 89.010 mm (3 5035 3.5043 inch)
Piston diameter coded grade 2 88.998 89.022 mm (3.5039 3.5048 inch)
Piston diameter coded grade 3 89.010 89.030 mm (3.5043 3.5051 inch)
Piston to cylinder bore clearance 0.012 - 0.022 mm (0.0005 inch)
Piston ring end gap compression (top, gauge diameter) 0.100 - 0.250 mm (0.0039 - 0.0098 inch)
Piston ring end gap compression (bottom, gauge diameter) 0.27 - 0.42 mm (0.0106 - 0.0165 inch)
Piston ring end gap oil ring (steel rail, gauge diameter) 0.15 0.65 mm (0.0059 0.0255 inch)
Piston ring end gap compression (top, service limit) 0.50 mm (0.0196 inch) maximum
Piston ring end gap compression (bottom, service limit) 0.65 mm (0.0255 inch) maximum
Piston ring end gap oil ring (steel rail, service) 0.90 mm (0.0354 inch) maximum
Piston ring groove width compression (top) 1.230 - 1.245 mm (0.0484 - 0.0490 inch)
Piston ring groove width * compression (bottom) 1.530 - 1.545 mm (0.0602 - 0.0608 inch)
Piston ring groove width oil ring 3.030 - 3.055 mm (0.1192 - 0.1203 inch)
Piston ring width
Piston ring to groove clearance
Piston pin bore diameter 21.017 - 21.031 mm (0.827 - 0.828 inch)
Piston pin diameter 21.011 - 21.013 mm (0.8272 inch)
Piston pin length 60.51 - 60.08 mm (2.382 - 2.365 inch)
Piston pin to piston fit -0.005 to +0.001 mm (0.0001 - 0.00003 inch)
Piston to connecting rod clearance
Connecting rod to pin clearance standard 0.004 - 0.020 mm (0.0001 - 0.0007 inch)
Connecting rod to pin clearance service limit 0.035 mm (0.0013 inch)
Connecting rod pin bore diameter
Connecting rod length (center to center) 138.06 - 138.14 mm (5.435 - 5.438 inch)
Connecting rod maximum allowed bend 0.038 mm (0.0015 inch) per25.0 mm (0.984 inch)
Connecting rod maximum allowed twist 0.050 mm (0.0019 inch) per 25.0 mm (0.984 inch)
Connecting rod bearing bore diameter
Connecting rod bearing to crankshaft 0.028 - 0.045 mm (0.0011 - 0.0017 inch)
clearance Connecting rod side clearance (assembled to crank) standard 0.100 - 0.30 mm (0.0039 - 0.0118 inch)
Connecting rod side clearance (assembled to crank) service limit 0.35 mm (0.0137 inch) maximum
Crankshaft Pulley
Install a new bolt. Tighten the bolt in 4 stages:
Stage 1: Tighten to 120 Nm (89 ft. lbs.).
Stage 2: Loosen one full turn (360 degrees).
Stage 3: Tighten to 50 Nm (37 ft. lbs.).
Stage 4: Tighten an additional 90 degrees.