Cylinder Block Assembly: Specifications

Cylinder Block
Cylinder bore
Diameter 96.82 mm (3.81 inch)
Maximum out-of-round limit 0.025 mm (0.001 inch)
Maximum taper 0.050 mm (0.002 inch)
Maximum out-of-round service limit 0.127 mm (0.005 inch)
Maximum taper service limit 0.254 mm (0.010 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)
No. 2 and No. 3 55.308-55.283 mm (2.177-2.176 inch)
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)

Crankshaft
Main bearing journal
Diameter
(Journals 1, 2, 3) 63.978-63.998 mm (2.5188-2.5196 inch)
Maximum taper 0.016 mm (0.0006 inch) diameter or 0.008 (0.0003 inch) radius MAX between any 2 measurement points
Maximum out-of-round 0.008 mm (0.0003 inch) MAX in 45 degrees, 0.016 mm (0.006 inch) TOTAL
Clearance-to-cylinder block
Desired 0.025-0.035 mm (0.001-0.0014 inch)
Allowable 0.013-0.058 mm (0.0005-0.0023 inch)
Connecting rod journal
Diameter 58.682-58.702 mm (2.310-2.311 inch)
Maximum taper 0.016 mm (0.0006 inch) diameter or 0.008 mm (0.0003 inch) radius between any 2 measurement points
Maximum out-of-round 0.008 mm (0.0003 inch) MAX in 45 degrees, 0.016 mm (0.006 inch) Total
Crankshaft maximum end play 0.10-0.20 mm (0.004-0.008 inch)

Piston
Diameter
Coded red (before coating) 96.795-96.782 mm (3.81082-3.81031 inch)
Coded blue (before coating) 96.808-96.795 mm (3.81133-3.81082 inch)
Coded yellow (before coating) 96.821-96.808 mm (3.81184-3.81133 inch)
Clearance-to-cylinder bore (uncoated clearance) 0.018-0.044 mm (0.00071-0.00173 inch)
Ring end gap
Compression (top, in gauge) 0.17-0.33 mm (0.0067-0.0130 inch)
Compression (bottom, in gauge) 0.3-0.55 mm (0.0118-0.0217 inch)
Oil ring (steel rail, in gauge) 0.15-0.65 mm (0.006-0.026 inch)
Ring groove width
Compression (top) 1.535-1.52 mm (0.0604-0.0598 inch)
Compression (bottom) -
Oil 3.05-3.03 mm (0.12001-0.11929 inch)
Ring width
Compression (top and bottom) 1.460-1.490 mm (0.05748-0.05866 inch)
Oil ring Side seal, snug fit ring
Ring-to-groove clearance
1st ring 0.030-0.065 mm (0.0012-0.00315 inch)
2nd ring 0.030-0.070 mm (0.0012-0.0028 inch)
Piston pin
Bore diameter 23.014-23.018 mm (0.90606-0.90622 inch)
Pin diameter 23.000-23.003 mm (0.90551-0.90563 inch)
Pin length 63.55-63.05 mm (2.5096-2.4823 inch)
Pin-to-piston fit 0.011-0.018 mm (0.00043-0.00071 inch)

Connecting Rod
Clearance-to-pin Press fit 8 kilonewtons (1,800 lb)
Pin bore diameter 22.94-22.98 mm (0.90315-0.90472 inch)
Rod length (center-to-center) 154.66-154.74 mm (6.08896-6.09211 inch)
Rod maximum allowable bend 0.04 per 25 mm (0.0016 per inch)
Rod maximum allowable twist 0.059 per 25 mm(0.002 per inch)
Rod bearing
Bore diameter 61.635-61.655 mm (2.4266-2.4274 inch)
Clearance-to-crankshaft
Desired 0.025-0.035 mm (0.001-0.0014 inch)
Allowable 0.022-0.069 mm (0.00086-0.0027 inch)
Rod side clearance (assembled to crank)
Standard 0.11-0.49 mm (0.0047-0.01929 inch)
Service limit 0.49 mm (0.0193 inch) max.

Balance Shaft
Journal diameter 52.108-52.082 mm (2.0515-2.0505 inch)
Bore inside diameter 55.689-55.664 mm (2.192-2.191 inch)
Maximum runout 0.025 mm (0.001 inch)
End play 0.075-0.200 mm (0.003-0.008 inch)

Main bearing Cap Bolts
First pass 55 Nm (41 ft. lbs).
Final pass Rotate additional 90°

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