System Specifications

SURFACE VARIATION - HEAD-TO-BLOCK

Deck surface must be within service limit of 0.050 mm (0.002 in.).

Cylinder Bore Diameter

Measure the cylinder bore at three levels in directions A and B. Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore.

A 88.000-88.010 mm (3.4645-3.4649 in.)
B 88.010-88.020 mm (3.4649-3.4653 in.)
C 88.020-88.030 mm (3.4653-3.4657 in.)

Cylinder Bore Diameter Taper (Max.) 0.028 mm (0.001 in.)

Cylinder Bore Out-of Round (Max.) 0.020 mm (0.0008 in.)

CRANKSHAFT

Main Bearing Journal Diameter - Journal Grade
0 51.985-51.988 mm (2.0466-2.0467 in.)
1 51.982-51.985 mm (2.0465-2.0466 in.)
2 51.979-51.982 mm (2.0464-2.0465 in.)
3 51.976-51.979 mm (2.0462-2.0464 in.)
4 51.973-51.976 mm (2.0461-2.0462 in.)

Journal Out-of-Round (Max.) 0.005 mm (0.0001 in.)

Journal Taper (Max.) 0.06 mm (0.002 in.)

End Play 0.05-0.25 mm (0.0019-0.0098 in.)

Wear Limit 0.30 mm (0.0118 in.)

Crankshaft damper-Bolt 210 Nm (155 ft. lbs)

MAIN BEARING

Main bearing diametrical clearance 0.028-0.048 mm (0.0011-0.0018 in.)
Main bearing diametrical clearance (Max) 0.058 mm (0.0022 in.)

Main Baring Selection Chart







There are three different size bearings available. The bearing class is read downward from top and corresponds to the front journal to the rear journal on the bottom.

UPPER MAIN BEARING SELECTION






Main Bearing Cap






CAUTION: There are different sets main bolts supplied with this engine. Each bolt set has a different torque value and engine damage could result if bolts are not torqued correctly. The bolts are not interchangeable.







If your bolt heads look like this (1,2), go to step A. If your bolt heads do not look like this (1,2), go to step B.

A. Tighten bolts using a three step method, in the sequence shown.
- Tighten bolts to 15 Nm (11 ft. lbs.)
- Tighten bolts to 27 Nm (20 ft. lbs.)
- Rotate an additional 45°.

B. Tighten bolts using a three step method, in the sequence shown.
- Tighten bolts to 15 Nm (11 ft. lbs.)
- Tighten bolts to 45 Nm (33 ft. lbs.)
- Rotate an additional 45°.


CONNECTING ROD

Bearing Clearance 0.032-0.060 mm (0.0012-0.0023 in.)
Wear Limit 0.070 mm (0.0027 in.)
Bore Diameter-Piston Pin 20.974-20.985 mm (0.8257-0.8261 in.)
Bore Diameter-Crankshaft End 51-51.015 mm (2.0078-2.0084 in.)
Side Clearance 0.1-0.25 mm (0.0039-0.00098 in.)
Wear Limit 0.27 mm (0.0106 in.)
Weight-Total (Less Bearing) 484 grams (17.07 oz.)

Connecting Rod Cap-Bolts 20 Nm ±90° (15 ft. lbs ±90°)

PISTON DIMENSIONS AND CLEARANCES

Piston Diameter
A 87.995-88.015 mm (3.4644-3.4652 in.)
B 88.005-88.025 mm (3.4648-3.4656 in.)
C 88.015-88.035 mm (3.4652-3.4659 in.)
Clearance to Bore (-0.015) - 0.015 mm [(-0.0006) - 0.0006 in.]
Weight 302-312 grams (10.65-11.00 oz.)
Land Clearance (Diametrical) 0.60-0.73 mm (0.0236-0.0287 in.)
Piston Length 51.5 mm (2.028 in.)
Piston Ring groove depth No. 1 3.51-3.68 mm (0.1382-0.0256 in.)
Piston Ring groove depth No. 2 4.05-4.25 mm0.1594-0.1673 in.)
Piston Ring groove depth No. 3 2.70-2.90 mm (0.1063-0.1142 in.)

PISTON RING GAP & GROOVE CLEARANCE
Ring Gap-Too Compression Ring 0.015-0.30 mm (0.0059-0.0118 in.)
Ring Gap-2nd Compression Ring 0.30-0.45 mm (0.0118-0.0177 in.)
Ring Gap-Oil Control Steel Rails 0.20-0.70 mm (0.0079-0.0276 in.)
Ring Side clearance-Compression Ring 0.03-0.07 mm (0.1182-0.0028 in.)
Ring Side clearance-Oil ring pack 0.06-0.15 mm (0.0024-0.0059 in.)

CRANKSHAFT PULLEY TORQUE

Crankshaft Damper-Bolt 210 Nm (155 ft. lbs.)