System Specifications
SURFACE VARIATION - HEAD-TO-BLOCKCheck 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 86.0 mm ±0.0076 (3.3859 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
Diameter 63.49-63.51 mm (2.4997-2.5004 in.)
Bearing Clearance 0.035-0.053 mm (0.0014-0.0021 in.)
Bearing Clearance (Max.) 0.087 mm (0.0034 in.)
Out of Round (Max.) 0.015 mm (0.0006 in.)
Taper (Max.) 0.015 mm (0.0006 in.)
End Play 0.0475-0.2725 mm (0.0019-0.0108 in.)
End Play (Max.) 0.43 mm (0.017 in.)
MAIN BEARING
Bearing Clearance 0.035-0.053 mm (0.0014-0.0021 in.)
Bearing Clearance (Max.) 0.087 mm (0.0034 in.)
Main bearing selection chart
cr09js1-348209_002
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, and lastly the main cap tie (horizontal) bolts.
Crankshaft Main Bearing Cap - Tie Bolts 28 Nm (250 in. lbs.).
Crankshaft Main Bearing Cap - Outer Cap Bolts 27 Nm + 1/4 turn (20 ft. lbs. + 1/4 turn)
Crankshaft Main Bearing Cap - Inner cap bolts 20 Nm + 1/4 turn (15 ft. lbs. + 1/4 turn).
CONNECTING ROD
Diameter 53.51-53.49 mm (2.1067-2.106 in.)
Bearing Clearance 0.024-0.064 mm (0.001-0.0026 in.)
Out of Round (Max.) 0.015 mm (0.0006 in.)
Taper (Max.) 0.015 mm (0.0006 in.)
Side Clearance 0.13-0.38 mm (0.0052-0.015 in.)
Side Clearance (Max.) 0.4318 mm (0.017 in.)
Piston Pin Bore Diameter 22.007-22.015 mm (0.8665-0.8668 in.)
Bearing Bore Out of Round (Max.) 0.004 mm (0.0002 in.)
Total Weight (Less Bearing) 529.9 ±7 grams (18.6917 ±0.247 oz.)
Connecting rod cap - Bolts 27 Nm +1/4 Turn (20 ft. lbs +1/4 Turn)
PISTON DIMENSIONS AND CLEARANCES
Piston Diameter 85.983 mm ±0.019 (3.3851 in. ±0.0017)
Clearance at Size location -0.0096 to +0.0436 mm (-0.0003 to +0.0016 in.)
Piston Weight 316-326 grams (11.1466-11.4994 oz.)
Piston Ring groove diameter-No. 1 77.8-78 mm
Piston Ring groove diameter-No. 2 75.9-76.1 mm
Piston Ring groove diameter-No. 3 76.5-76.7 mm
PISTON RING GAP
Ring gap-Top Compression Ring 0.20-0.36 mm (0.008-0.014 in.)
Ring gap-2nd Compression Ring 0.37-0.63 mm (0.0146-0.0249 in.)
Ring Gap-Oil Control (steel Rails) 0.25-0.76 mm (0.010-0.030 in.)
PISTON RING SIDE CLEARANCE
Compression Ring-Top 0.035-0.083 mm (0.0013-0.0032 in.)
Compression Ring-Second 0.040-0.080 mm (0.0016-0.0031 in.)
Oil Ring (Steel Rails) 0.058-0.204 mm (0.0022-0.0080 in.)
CRANKSHAFT PULLEY TORQUE
Crankshaft Damper-Bolt 170 Nm (125 ft. lbs.)