System Specifications

SURFACE VARIATION - HEAD-TO-BLOCK

Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.).

Cylinder Bore Diameter

Cylinder Bore Diameter 96.0 mm ±0.0076 (3.780 in. ±0.0003)
Out of Round (Max.) 0.076 mm (0.003 in.)
Taper (Max.) 0.051 mm (0.002 in.)

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.

CRANKSHAFT
Main Journal Diameter 63.987-64.013 mm (2.5192-2.5202 in.)
Main Bearing Diametrical Clearance 0.032-0.062 mm (0.0013-0.0024 in.)
Bearing Clearance (Wear Limit) 0.070 mm (0.0027 in.)
DIA Out-of Round (MAX) 0.007 mm (0.0003 in.)
Diametrical Taper (MAX) 0.006 mm (0.00025 in.)
End Play 0.048-0.260 mm (0.002-0.010 in.)
End Play (MAX) 0.330 mm (0.013 in.)

MAIN BEARING

Main Bearing Diametrical Clearance 0.032-0.062 mm (0.0013-0.0024 in.)
Bearing Clearance (Wear Limit) 0.070 mm (0.0027 in.)
DIA Out-of Round (MAX) 0.007 mm (0.0003 in.)
Diametrical Taper (MAX) 0.006 mm (0.00025 in.)

Main Bearing Selection Chart






MAIN BEARING CAP

NOTE: The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts.

Inner main bearing cap bolts 20 Nm + 1/4 turn (15 ft. lbs. + 1/4 turn).
Outer Main Cap Bolts 27 Nm + 1/4 turn (20 ft. lbs. + 1/4 turn)
Tie Bolts (Horizontal) 28 Nm (250 in. lbs.).

CONNECTING ROD

Diameter 57.982-58.002 mm (2.282-2.283 in.)
Bearing Diametrical Clearance 0.024-0.054 mm (0.0009-0.0021 in.)
Bearing Clearance (Wear Limit) 0.062 mm (0.0024 in.)
Out-of-Round (MAX) 0.007 mm (0.0003 in.)
Diametrical Tapper (MAX) 0.006 mm (0.00025 in.)

Rod Pin Bore Diameter 22.010-22.020 mm (0.8665-0.8669 in.)
Side Clearance 0.39 mm (0.0153 in.)
Total Weight (Less Bearing) 693 grams (24.445 oz.)

Connecting Rod cap - Bolts 27 +1/4 Turn (20 +1/4 Turn)

PISTON DIMENSIONS AND CLEARANCES

Piston Diameter 95.98 mm ±0.019 (3.7788 in. ±0.0008 in.)
Clearance at Size location -0.007 to +0.047 mm (-0.0003 to +0.0018 in.)
Piston Pin bore diameter 22.005-22.012 mm (0.8663-0.8666 in.)
Piston Weight-A 404.5-409.5 grams (14.27-14.44 oz.)
Piston Weight-B 399.5-404.5 grams(14.09-14.27 oz.)
Piston Ring groove diameter #1 87.4-87.6 mm (3.441-3.449 in.)
Piston Ring groove diameter #2 86.3-86.5 mm (3.397-3.4055 in.)
Piston Ring groove diameter #3 85.8-86.0 mm (3.378-3.385 in.)

PISTON RING GAP

Ring gap-Top Compression Ring 0.20-0.36 mm (0.008-0.014 in.)
Ring gap-2nd Compression Ring (Micro-Napier) 0.20-0.40 mm (0.0078-0.0157 in.)
Ring Gap-Oil Control (steel Rails) 0.25-0.76 mm (0.010-0.030 in.)

PISTON RING SIDE CLEARANCE

Top and Second Compression Ring 0.040-0.080 mm (0.0016-0.0031 in.)
Oil Ring (Steel Rails) 0.038-0.184 mm (0.0015-0.0073 in.)

CRANKSHAFT PULLEY TORQUE

Crankshaft Damper - Bolt 95 Nm (70 ft. lbs.)