System Specifications

SURFACE VARIATION

Deck surface 0.1 mm (0.004 in.)

CYLINDER BLOCK

Cylinder Bore Diameter 87.4924-87.5076 mm (3.4446-3.4452 in.)
Taper (Max.) 0.051 mm (0.002 in.)
Out-of-Round (Max.) 0.051 mm (0.002 in.)

CRANKSHAFT

Main Bearing Journal Diameter 59.992 - 60.008 mm (2.362 - 2.3625 in.)
Journal Out-of-Round (Max.) 0.0035 mm (0.0003 in.)
Journal Taper (Max.) 0.007 mm (0.0001 in.)
End Play 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Wear Limit 0.38 mm (0.015 in.)
Main Bearing Diametrical Clearance 0.018 - 0.062 mm (0.0007 - 0.0024 in.)

Bore Diameter-Crankshaft End
Non-Turbo 52.993-53.007 mm (2.0863-2.0868 in.)
Turbo 52.992-53.008 mm (2.0862-2.0869 in.)

MAIN BEARING

Main Bearing Journal Diameter 59.992 - 60.008 mm (2.362 - 2.3625 in.)
Journal Out-of-Round (Max.) 0.0035 mm (0.0003 in.)
Journal Taper (Max.) 0.007 mm (0.0001 in.)
End Play 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Wear Limit 0.38 mm (0.015 in.)
Main Bearing Diametrical Clearance 0.018 - 0.062 mm (0.0007 - 0.0024 in.)

MAIN BEARING CAP





Tighten bolts (1-10) again to 41 Nm (30 ft. lbs.) in sequence shown.
Install main bearing bed plate to engine block bolts (11-20), and torque each bolt to 28 Nm (250 in. lbs.) in sequence shown.
Tighten bolts (1-10) to 75 Nm (55 ft. lbs.) in sequence shown.
Tighten bolts (11-20) again to 28 Nm (250 in. lbs.) in sequence shown.


CONNECTING ROD

Connecting Rod Journal Diameter 49.984 - 50.000 mm (1.968 - 1.9685 in.)
Bearing Clearance 0.025-0.071 mm (0.0009-0.0027 in.)
Wear Limit 0.075 mm (0.003 in.)
Side Clearance 0.13-0.38 mm (0.005-0.015 in.)
Wear Limit 0.40 mm (0.016 in.)

Weight-Total (Less Bearing)

Non-Turbo 565.8 grams (19.96 oz.)
Turbo 663.5 grams (23.4 oz.)

PISTONS

Piston Diameter
Non-Turbo 87.456-87.474 mm (3.4431-3.4439 in.)
Turbo 87.436-87.454 mm (3.4424-3.4431 in.)

Clearance @ 24.6 mm (0.551 in.) from bottom of skirt (Non-Turbo) 0.018-0.0516 mm (0.0007-0.0020 in.)
Clearance @ 22 mm (0.866 in.) from bottom of skirt (Turbo) 0.046-0.064 mm (0.0018-0.0025 in.)

Weight
Non-Turbo 345-355 grams (12.17-12.52 oz.)
Turbo 331-339 grams (11.67-11.95 oz.)

Land Clearance (Diametrical)

Non-Turbo 0.563-0.621 mm (0.022-0.024 in.)
Turbo 0.556-0.674 mm (0.021-0.027 in.)

Piston Length

Non-Turbo 66.25 mm (2.608 in.)
Turbo 61.43 mm (2.419 in.)

PISTON RINGS

Ring Gap-Top Compression Ring

Non-Turbo 0.25-0.51 mm (0.0098-0.020 in.)
Turbo 0.20-0.40 mm (0.0078-0.0157 in.)
Wear Limit 0.8 mm (0.031 in.)

Ring Gap-2nd Compression Ring

Non-Turbo 0.23-0.48 mm (0.009-0.018 in.)
Turbo 0.20-0.40 mm (0.007-0.015 in.)
Wear Limit 0.8 mm (0.031 in.)

Ring Gap-Oil Control Steel Rails

Non-Turbo 0.25-0.64 mm (0.009-0.025 in.)
Turbo 0.15-0.66 mm (0.005-0.025 in.)
Wear Limit 1.0 mm (0.039 in.)

Ring Side Clearance-Compression Rings

Non-Turbo 0.030-0.080 mm (0.0011-0.0031 in.)
Turbo 0.035-0.085 mm (0.001-0.003 in.)
Wear Limit 0.10 mm (0.004 in.)

Ring Side Clearance-Oil Ring Pack

Non-Turbo 0.012-0.178 mm (0.0004-0.0070 in.)
Turbo 0.027-0.176 mm (0.001-0.006 in.)

CRANKSHAFT PULLEY

Crankshaft Damper - Bolt 136 Nm (100 ft. lbs.)