Cylinder Block Assembly: Specifications
Cylinder BlockHead gasket surface flatness 0.50 mm (0.002 in.) for 150 x 150 mm (5 x 5 in.) area 0.25 mm (0.001 in.) for 25 x 25 mm (l x 1 in.) area 0.120 mm (0.005 in.) overall
Head gasket thickness 1.0 mm (0.40 in.)
Main bearing bore diameter 67.998-68.022 mm (2.677-2.6780 in.)
Cylinder bore
Diameter
Grade 1 89.000-89.010 mm (3.50393-3.504323 in.)
Grade 2 89.010-89.020 mm (3.504323-3.504717 in.)
Grade 3 89.020-82.030 mm (3.504717-3.50511 in.)
Out-of-round limit 0.015 mm (.0005 in.)
Out-of-round service limit 0.020 mm (.0007 in.)
Taper service limit 0.020 mm (0.008 in.)
Crankshaft
Main bearing journal diameter 62.968-62.992 mm (2.467-2.479 in.)
Connecting rod journal diameter 49.970-49.990 mm (1.967-1.968 in.)
Crankshaft free cod play 0.110-0.232 mm (0.004-0.009 in.)
Crankshaft runout to rear face of cylinder block 0.050 mm (in.) max. 0.001 in.)
Connecting rod bearings
Clearance to crankshaft 0.028-0.066 mm (0.001-0.0025 in.)
Bearing wall thickness (std.) c 1.503 mm (.059 in.)
Main bearings
Clearance to crankshaft-desired 0.025-0.045 mm 0.0009-0.0017 in.)
Clearance to crankshaft-allowable 0.025-0.050 mm (0.0009-0.0019 in.)
Bearing wall thickness-grade 1 2.497 mm (0.0983 in.)
Bearing wall thickness-grade 2 2.501 mm (0.0985 in.)
Bearing wall thickness-grade 3 2.505 mm (0.0986 in.)
Connecting Rod
Piston pin bore diameter 21.017-21.031 mm (0.827-0.828 in.)
Crankshaft bearing bore diameter 53.015-53.035 mm (2.0872-2.0879 in.)
Length (center to center) 138.06-138.14 mm (5.435-5.38 in.)
Alignment (bore to bore max. difference) d
Twist 0.050 mm per 25 (0.0019 per 0.984 in.)
Bend 0.038 mm per 25 (0.0014 per 0.984 in.)
Side clearance (assembled to crank)
Piston
Piston diameter
Coated grade 1 e 88.990-89.010 mm (3.5035-3.5043 in.)
Coated grade 2 88.998-89.022 mm (3.5039-3.5048 in.)
Coated grade 3 89.010-89.030 mm (3.5043-3.5051 in.)
Uncoated grade 1 88.970-88.980 mm (3.50275-3.50314 in.)
Uncoated grade 2 88.978-88.992 mm (3.50306-3.50362 in.)
Uncoated grade 3 89.010-89.030 mm (3.50432-3.50511 in.)
Piston-to-bore clearance 0.012 to 0.022 mm (0.0005-0.0009 in.)
Pin bore diameter (piston) 21.008-21.012 mm (0.8270-0.8272 in.)
Ring groove width
Compression (top) 1.230-1.245 mm (0.0484-0.0490 in.)
Compression (bottom) 1.530-1.545 mm (0.0602-0.0608 in.)
Oil ring 3.030-3.055 mm (0.1192-0.0120 in.)
Piston pin
Length 60.51-60.08 mm (2.382-2.365 in.)
Diameter 21.011-21.013 mm (0.0013 in.)
Pin-to-piston clearance -0.005 to +0.001 mm (0.0001-0.00003 in.)
Pin-to-rod clearance
Standard 0.004-0.020 mm (0.0001-0.0007 in.)
Service limit 0.035 mm (0.0013 in.)
Piston Ring-To-Groove Clearance
Compression (top) 0.040-0.075 mm (0.0015-0.0029 in.)
Compression (bottom) 0.040-0.085 mm (0.0015-0.0033 in.)
Oil ring Snug Fit
Piston ring gap f
Compression (top)-gauge diameter 0.100-0.250 mm (0.0039-0.0098 in.)
Compression (bottom)-gauge diameter 0.27-0.42 mm (0.0106-0.0165 in.)
Oil ring (steel rail)-gauge diameter 0.15-0.65 mm (0.0059-0.0255 in.)
Compression (top)-service limit 0.50 mm (0.0196 in.) max.
Compression (bottom)-service limit 0.65 mm (0.0255 in.) max.
Oil ring (steel rail)-service limit 0.90 mm (0.0354 in.) max.
c 0.250 mm Undersize-Add 0.125 mm to standard or grade 2 thickness.
d Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar. 101.5 mm on each side of rod centerline.
e Measured at 50 mm (1.9685 in.) from outer perimeter top of piston to the pin axis.
f Specification 82.4 mm (3.2441 in.) diameter gauge.
Lower cylinder block bolts and studs
Fasteners No. 1, 5, 6, 7, 8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 79.3 mm (0.05 inch x 3.12 in.) bolts. Fasteners No. 2-4,17 are M8 x 1.25 mm x 95.3 mm (0.05 inch x 3.75 in.) bolts. Fasteners 9-16 are M10 x 1.5 mm x 106 mm (0.06 inch x 4.17 in.) bolts. The bolts and studs must be installed in the correct position or engine damage can result.
Stage 1 fasteners 1-8 to 25 Nm (18 ft. lbs.)
Stage 2 fasteners 9-16 to 40 Nm (30 ft. lbs.)
Stage 3 fasteners 1-16 to 90 degrees
Stage 4 fasteners 17-22 to 25 Nm (18 ft. lbs.)
Connecting rod caps bolts
Stage 1 23 Nm (17 ft. lbs.)
Stage 2 43 Nm (32 ft. lbs.)
Crankshaft pulley bolt
Stage 1 120 Nm (86 ft. lbs.)
Stage 2 Loosen 360 degrees
Stage 3 50 Nm (37 ft. lbs.)
Stage 4 additional 90 degrees