System Specifications
Cylinder BlockThe cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area or scratches longer than 0.0254 mm (0.001 inch).
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 0.013 mm (0.0005 inch)
Maximum out-of-round 0.010 mm (0.0004 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 (2.6568 - 2.6576 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum out-of-round between cross sections 0.0075 mm (0.0003 inch)
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 between cross sections 0.0075 mm (0.0003 inch)
Crankshaft maximum end play 0.075 - 0.377 mm (0.0030 - 0.0148 inch)
Piston
Piston diameter
Grade 1 (at right angle to pin bore) 90.175 - 90.165 mm (3.5502 - 3.5498 inch)
Grade 2 (at right angle to pin bore) 90.185 - 90.175 mm (3.5506 - 3.5502 inch)
Grade 3 (at right angle to pin bore) 90.195 - 90.185 mm (3.5510 - 3.5506 inch)
Piston-to-cylinder bore clearance (at grade size) 0.005 - 0.025 mm (0.0002 - 0.0010 inch)
Ring end gap
Top 0.15 - 0.30 mm (0.0059 - 0.0118 inch)
Intermediate 0.25 - 0.50 mm (0.0098 - 0.0196 inch)
Oil control 0.15 - 0.65 mm (0.0059 - 0.0256 inch)
Ring groove width
Top 1.502 - 1.505 mm (0.0591 - 0.0592 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 1.49 - 1.46 mm (0.0587 - 0.0575 inch)
Ring-to-groove clearance
Top 0.030 - 0.050 mm (0.0012 - 0.0020 inch)
Intermediate 0.030 - 0.080 mm (0.0012 - 0.0031 inch)
Piston pin
Bore diameter 22.008 - 22.014 mm (0.8665 - 0.8667 inch)
Pin diameter 22.0005 - 22.0030 mm (0.8662 - 0.8663 inch)
Pin 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)
Rod length (center-to-center) 169.1 mm (6.6575 inch)
Rod maximum allowed bend 0.038 mm (0.0015 inch)
Rod maximum allowed twist a 0.05 mm (0.0020 inch)
Bearing bore diameter (with assembled liners) 53.049 - 53.027 mm (2.0885 - 2.0877 inch)
Bearing-to-crankshaft clearance 0.066 - 0.024 mm (0.0025 - 0.0009 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
Remove and discard the main bearing cap bolts.
Vertical main bearing cap fasteners
First pass 40 Nm (30 ft. lbs.)
Final pass tighten 90°
Remove and discard the cross-mounted main cap bolts.
Side bolts
First pass 30 Nm (22 ft. lbs.)
Final pass tighten 90°
Crankshaft Pulley Bolt
Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
First pass 90 Nm (66 ft. lbs.)
Second pass loosen 360°
Third pass 50 Nm (37 ft. lbs.)
Final pass tighten 90°