Cylinder Block Assembly: Specifications
Cylinder BlockCylinder head gasket surface flatness 0.18 mm (0.007 in.)
Cylinder bore diameter 96.82 mm (3.81 in.)
Cylinder bore maximum out-of-round limit 0.025 mm (0.001 in.)
Cylinder bore maximum taper 0.050 mm (0.002 in.)
Cylinder bore maximum out-of-round limit 0.025 mm (0.001 in.)
Cylinder bore maximum taper service limit 0.254 mm (0.010 in.)
Main bearing bore inside diameter 68.905 mm (2.713 in.), 68.885 mm (2.712 in.)
Crankshaft
Crankshaft maximum end play 0.010-0.20 mm (0.0004-0.008 in.)
Main bearing journal diameter (journals 1, 2,3) 63.978-63.998 mm (2.5188-2.5196 in.)
Main bearing journal maximum taper 0.016 mm (0.0006 in.) diameter or 0.008 mm (0.0003 in.) radius MAX between any 2
Main bearing journal maximum out-of-round 0.0008 mm MAX in 45 degrees, 0.016 mm (0.006 in.) TOTAL
Main bearing journal-to-cylinder block clearance - desired 0.025-0.035 mm (0.001-0.0014 in.)
Main bearing journal-to-cylinder block clearance - allowable 0.013-0.058 mm (0.0005-0.0023 in.)
Main Bearing Cap
Tighten in 2 stages:
Stage 1 55 Nm (41 ft. lbs.).
Stage 2 Rotate an additional 90 degrees.
Connecting Rod
Connecting rod side clearance - standard 0.11-0.49 mm (0.0047-0.0193 in.)
Connecting rod side clearance - service limit 0.49 mm MAX (0.0193 in. MAX)
Connecting rod bearing-to-crankshaft clearance - desired 0.025-0.035 mm (0.001-0.0014 in.)
Connecting rod bearing-to-crankshaft clearance - allowable 0.022-0.069 mm (0.00086-0.0027 in.)
Piston
Piston diameter - coded red (before coating) 96.795-96.782 mm (3.81082-3.81031 in.)
Piston diameter - coded blue (before coating) 96.808-96.795 mm (3.81133-3.81082 in.)
Piston diameter - coded yellow (before coating) 96.821-96.808 mm (3.81184-3.81133 in.)
Piston-to-cylinder bore clearance (uncoated clearance) 0.018-0.044 mm (0.0007-0.0017 in.)
Piston ring end gap-compression (top, in gauge) 0.17-0.33 mm (0.0067-0.0130 in.)
Piston ring end gap-compression (bottom, in gauge) 0.3-0.55 mm (0.0 118-0.0217 in.)
Piston ring end gap - oil ring (steel rail, in gauge) 0.15-0.65 mm (0.0059-0.0256 in.)
Piston ring groove width - compression (top) 1.535-1.52 mm (0.0604-0.0598 in.)
Piston ring groove width - compression (bottom) 1.54-1.52 mm (0.0606-0.0598 in.)
Piston ring groove width - oil 3.05-3.03 mm (0.1200-0.1193 in.)
Piston ring width-compression (top) 1.47-1.49 mm (0.0578-0.0587 in.)
Piston ring width - compression (bottom) 1.47-1.49 mm (0.0578-0.0587 in.)
Piston ring width - oil ring side seal - snug fit
Piston ring-to-groove clearance - 1st ring 0.030-0.065 mm (0.0012-0.0026 in.)
Piston ring-to-groove clearance - 2nd ring 0.030-0.070 mm (0.0012-0.0028 in.)
Piston pin bore diameter 23.012-23.012 mm (0.9060-0.9061 in.)
Piston pin diameter 23.000-23.003 mm (0.9055-0.9056 in.)
Piston pin length 63.55-63.05 mm (2.5096-2.4823 in.)
Piston pin-to-piston fit 0.009-0.017 mm (0.0004-0.0007 in.)
Crankshaft Pulley Bolt 160 Nm (118 ft. lbs.)