System Specifications

Cylinder Block
Cylinder bore
Diameter 90.213-90.226 (grade 2)
Maximum taper 0.013 mm (0.00051 inch)
Maximum out-of-round 0.015 mm (0.00059)
Main bearing bore inside diameter 72.40-72.424 mm (2.8504-2.8513 inch)

Crankshaft
Main bearing journal
Diameter 67.483-67.503 mm (2.6568-2.6576 inch)
Maximum taper 0.004 mm (0.0002 inch)
Maximum-out-of-round 0.0075 mm (0.0003 inch) between cross sections
Clearance-to-cylinder block 0.066-0.024 mm (0.0259-0.0009 inch)
Connecting rod journal
Diameter 53.003-52.983 mm (2.0867-2.0859 inch)
Maximum taper (straightness) 0.004 mm (0.0002 inch)
Maximum-out-of-round 0.0075 mm (0.0003 inch) between cross sections
Maximum end play 0.301 mm (0.0118 inch)

Jack Screws





First pass 5 Nm (44 lb-in).
Final pass 10 Nm (89 lb-in).

Side Bolts
Discard the bolts.





First pass 10 Nm (89 lb-in).
Final pass 21 Nm (15 lb-ft).

Lower Bolts
Discard the bolts.





First pass 40 Nm (30 lb-ft).
Final pass Tighten an additional 90°

Crankshaft Main Bearing Codes














Connecting Rod
Clearance-to-pin 0.016-0.038 mm (0.0006-0.0015 inch)
Pin bore diameter 22.02-22.01 mm (0.8671-0.8666 inch)
Length (centerline bore-to-bore) 150.7 mm (5.9330 inch)
Maximum allowable bend ±0.038 mm (0.0015 inch)
Maximum allowable twist ±0.05 mm (0.0019 inch)
Bearing bore diameter 56.86-56.89 mm (2.2388-2.2396 inch)
Bearing-to-crankshaft clearance 0.06-0.02 mm (0.0026-0.0010 inch)
Side clearance
Standard 0.015-0.45 mm (0.0006-0.0177 inch)
Maximum 0.50 mm (0.0197 inch)

Connecting Rod Bolts
Discard the bolts.





First pass 23 Nm (17 lb-ft).
Second pass 43 Nm (32 lb-ft).
Final pass Rotate an additional 90-120°

Piston
Diameter
Grade 1 90.191-90.206 mm (3.5508-3.5514 inch)
Grade 2 90.203-90.220 mm (3.5513-3.5519 inch)
Grade 3 90.217-90.232 mm (3.5518-3.5524 inch)
Clearance-to-cylinder bore @ 43 mm from top a -0.005 to + 0.025 mm (-0.0002 to + 0.0010 inch)
a New pistons have a coating that may cause the piston-to-bore clearance to read negative, indicating the piston is slightly larger than the bore. This coating will wear off and should not be a cause of concern.
Pin bore diameter 22.0065-22.0110 mm (0.8664-0.8666 inch)

Piston Rings
End gap
Top 0.15-0.30 mm (0.0059-0.0118 inch)
Intermediate 0.15-0.30 mm (0.0059-0.0118 inch)
Oil control 0.15-0.30 mm (0.0059-0.0118 inch)
Ring groove width
Top 1.520-1.540 mm (0.0598-0.0606 inch)
Intermediate 1.520-1.540 mm (0.0598-0.0606 inch)
Oil control 3.03-3.055 mm (0.1193-0.1203 inch)
Ring width
Top 1.5 mm (0.05 inch)
Intermediate 1.5 mm (0.05 inch)
Ring-to-groove clearance
Top 0.020-0.060 mm (0.0008-0.0024 inch)
Intermediate 0.020-0.060 mm (0.0008-0.0023 inch)
Oil control 0.030-0.070 mm (0.0012-0.0028 inch)

Piston Pin
Diameter 21.995-21.997 mm (0.8659-0.8660 inch)
Length 61.870-62.120 mm (2.4358-2.4456 inch)
Fit-to-piston 0.0095-0.016 mm (0.0004-0.0006 inch)
Clearance-to-connecting rod 6.58-7.58 mm (0.259-0.298 inch)

Crankshaft Pulley Bolt
First pass 120 Nm (89 lb-ft).
Second pass Loosen bolt one full turn
Third pass 50 Nm (37 lb-ft).
Final pass Tighten an additional 90°