Operation CHARM: Car repair manuals for everyone.

System Specifications

Pistons
Diameter 81.975-81.993 mm (3.2274-3.2281 in.)
Piston-to-Cylinder Bore Clearance - Standard 0.007-0.038 mm (0.0003-0.0015 in.)
Piston-to-Cylinder Bore Clearance - Maximum 0.10 mm (0.0039 in.)
Ring End Gap - Lower Ring - Maximum 1.20 mm (0.0472 in.)
Ring End Gap - Lower Ring - Standard 0.35-0.50 mm (0.0138-0.0197 in.)
Ring End Gap - Oil Ring - Maximum 1.05 mm (0.0413 in.)
Ring End Gap - Oil Ring - Standard 0.15-0.40 mm (0.0059-0.0157 in.)
Ring End Gap - Top Ring - Maximum 1.05 mm (0.0413 in.)
Ring End Gap - Top Ring - Standard 0.25-0.35 mm (0.0098-0.0138 in.)
Ring Groove Clearance - Lower Compression Ring 0.030-0.070 mm (0.0012-0.0028 in.)
Ring Groove Clearance - Upper Compression Ring 0.020-0.070 mm (0.0009-0.0028 in.)

Connecting Rods and Bearings
Connecting Rod Bearing Clearance - Maximum 0.080 mm (0.0031 in.)
Connecting Rod Bearing Clearance - Standard 0.028-0.052 mm (0.0011-0.0020 in.)
Connecting Rod Bolt Diameter - Minimum 6.4 mm (0.252 in.)
Connecting Rod Bolt Diameter - Standard 6.0-6.7 mm (0.260-0.264 in.)
Connecting Rod Bow - Maximum 0.050 mm (0.0020 in.)
Connecting Rod Bushing inside Diameter 20.011-20.023 mm (0.7878-0.7883 in.)
Connecting Rod Side Clearance - Maximum 0.35 mm (0.0138 in.)
Connecting Rod Side Clearance - Standard 0.160-0.342 mm (0.0063-0.0135 in.)
Connecting Rod Thickness 19.788-19.840 mm (0.7791-0.7811 in.)
Connecting Rod Twist - Maximum 0.15 mm (0.0059 in.)
Rod Bearing Thickness - "1"�Stamping 1.482-1.486 mm (0.0583-0.0585 in.)
Rod Bearing Thickness - "2"�Stamping 1.486-1.490 mm (0.0585-0.0587 in.)
Rod Bearing Thickness - "3"�Stamping 1.490-1.494 mm (0.0587-0.0588 in.)
Rod Bushing Oil Clearance - Piston To Piston Pin 0.005-0.0013 mm (0.0002-0.0005 in.)

Crankshaft
Crankshaft Diameter 43.992-44.000 mm (1.7320-1.7328 in.)
Crankshaft Diameter Out-of-Round and Taper - Maximum 0.02 mm (0.0004 in.)
Journal Taper or Out-of-Round 0.02 mm (0.0008 in.)
Runout at Center Journal 0.03 mm (0.0012 in.)
Thrust Bearing Thickness 1.930-1.980 mm (0.0760-0.0780 in.)
Thrust Play - Maximum 0.30 mm (0.0118 in.)
Thrust Play - Standard 0.04-0.24 mm (0.0016-0.0094 in.)

Main Bearings
Crankshaft Journal Diameter - "0"�Stamping 47.998-48.000 mm (1.8897-1.8898 in.)
Crankshaft Journal Diameter - "1"�Stamping 47.996-47.998 mm (1.8896-1.8897 in.)
Crankshaft Journal Diameter - "2"�Stamping 47.994-47.996 mm (1.8895-1.8896 in.)
Crankshaft Journal Diameter - "3"�Stamping 47.992-47.994 mm (1.8894-1.8895 in.)
Crankshaft Journal Diameter - "4"�Stamping 47.990-47.992 mm (1.8893-1.8894 in.)
Crankshaft Journal Diameter - "5"�Stamping 47.988-47.990 mm (1.8892-1.8893 in.)
Crankshaft Thrust Washer Clearance - Maximum 0.08 mm (0.0031 in.)
Crankshaft Thrust Washer Clearance - Standard 0.016-0.032 mm (0.0006-0.0013 in.)
Main Bearing Thrust Clearance - Maximum 0.30 mm (0.0118 in.)
Main Bearing Thrust Clearance - Standard 0.02-0.22 mm (0.0008-0.0087 in.)
Main Bearing Thickness - "1"�Stamping 1.989-1.992 mm (0.0783-0.0784 in.)
Main Bearing Thickness - "2"�Stamping 1.992-1.995 mm (0.0784-0.0785 in.)
Main Bearing Thickness - "3"�Stamping 1.995-1.998 mm (0.0785-0.0787 in.)
Main Bearing Thickness - "4"�Stamping 1.998-2.001 mm (0.0787-0.0788 in.)
Main Bearing Thickness - "5"�Stamping 2.001-2.004 mm (0.0788-0.0789 in.)

Cylinder Block Main Journal Bore Diameter (A)
Main Journal Bore Diameter - "0"�Mark 52.000-52.003 mm (2.0472-2.0473 in.)
Main Journal Bore Diameter - "1"�Mark 52.003-52.005 mm (2.0473-2.0474 in.)
Main Journal Bore Diameter - "2"�Mark 52.005-52.007 mm (2.0474-2.0475 in.)
Main Journal Bore Diameter - "3"�Mark 52.007-52.010 mm (2.0475-2.0476 in.)
Main Journal Bore Diameter - "4"�Mark 52.010-52.012 mm (2.0476-2.0477 in.)
Main Journal Bore Diameter - "5"�Mark 52.012-52.014 mm (2.0477-2.0478 in.)
Main Journal Bore Diameter - "6"�Mark 52.014-52.016 mm (2.0478-2.0479 in.)

Crankshaft Main Journal Diameter (B)
Main Journal Diameter - "0"�Mark 47.998-48.000 mm (1.8897-1.8898 in.)
Main Journal Diameter - "1"�Mark 47.996-47.998 mm (1.8896-1.8897 in.)
Main Journal Diameter - "2"�Mark 47.994-47.996 mm (1.8895-1.8896 in.)
Main Journal Diameter - "3"�Mark 47.992-47.994 mm (1.8894-1.8895 in.)
Main Journal Diameter - "4"�Mark 47.990-47.992 mm (1.8893-1.8894 in.)
Main Journal Diameter - "5"�Mark 47.988-47.990 mm (1.8892-1.8893 in.)
Standard Bearing Center Wall Thickness - "1"�Mark 1.993-1.996 mm (0.0785-0.0786 in.)
Standard Bearing Center Wall Thickness - "2"�Mark 1.996-1.999 mm (0.0786-0.0787 in.)
Standard Bearing Center Wall Thickness - "3"�Mark 1.999-2.002 mm (0.0787-0.0788 in.)
Standard Bearing Center Wall Thickness - "4"�Mark 2.002-2.003 mm (0.0788-0.0789 in.)