System Specifications
Bore 96.82 mm (3.81 inch)Stroke 95.0 mm (3.8 inch)
Cylinder Block
Cylinder bore diameter 96.812 mm (3.81 inch)
Cylinder bore maximum out-of-round limit 0.025 mm (0.001 inch)
Cylinder bore maximum taper 0.050 mm (0.002 inch)
Cylinder bore maximum out-of-round service limit 0.127 mm (0.005 inch)
Cylinder bore 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)
Head gasket surface flatness 0.008 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)
Main bearing journal maximum taper 0.016 mm (0.0006 inch) diameter or 0.008 (0.0003 inch) radius MAX between any 2 measurement points
Main bearing journal maximum out-of-round 0.008 mm (0.0003 inch) MAX in 45 degrees, 0.016 mm (0.006 inch) TOTAL
Main bearing journal-to-cylinder block clearance - desired 0.025-0.035 mm (0.001-0.0014 inch)
Main bearing journal-to-cylinder block clearance - 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)
Connecting rod journal maximum taper 0.016 mm (0.0006 inch) diameter or 0.008 mm (0.0003 inch) radius between any 2 measurement points
Connecting rod journal 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 and Connecting Rod
Piston diameter - coded red (before coating) 96.795-96.782 mm (3.81082-3.81031 inch)
Piston diameter - coded blue (before coating) 96.808-96.795 mm (3.81133-3.81082 inch)
Piston diameter - coded yellow (before coating) 96.821-96.808 mm (3.81184-3.81133 inch)
Piston-to-cylinder bore clearance (uncoated clearance) 0.018-0.044 mm (0.00071-0.00173 inch)
Piston ring end gap - compression (top, in gauge) 0.17-0.33 mm (0.0067-0.0130 inch)
Piston ring end gap - 0.3-0.55 mm compression (bottom, in gauge) (0.0118-0.0217 inch)
Piston ring end gap - oil ring (steel rail, in gauge) 0.15-0.65 mm (0.006-0.026 inch)
Piston ring groove width - compression (top) Piston ring groove width - compression (bottom) 1.535-1.52 mm (0.0603-0.0598 inch)
Piston ring groove width - oil 3.05-3.03 mm (0.12001-0.11929 inch)
Piston ring width compression (top and bottom) 1.460-1.490 mm (0.05748-0.05866 inch)
Piston ring width - oil ring Side seal, snug fit
Piston ring-to-groove clearance - 1st ring 0.030-0.065 mm (0.0012-0.00315 inch)
Piston ring-to-groove clearance - 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)
Piston pin diameter 23.000-23.003 mm (0.90551-0.90563 inch)
Piston pin length 63.55-63.05 mm (2.5096-2.4823 inch)
Piston pin-to-piston fit 0.011-0.018 mm (0.00043-0.00071 inch)
Connecting Rod Cap
Tighten the 2 connecting rod cap bolts in 3 stages.
^ Stage 1: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 3: Tighten an additional 105 degrees.
Install the crankshaft pulley washer and the bolt.
^ Tighten to 160 Nm (118 ft. lbs.).
Crankshaft main bearing cap bolts
Install the main bearing caps. Tighten the bolts in 2 stages.
^ Stage 1: Tighten to 55 Nm (41 ft. lbs.).
^ Stage 2: Rotate an additional 90 degrees.