Cylinder head
Maximum non-flatness of the bottom surface: | ||
– 4-cylinder petrol engines: | ||
• parallel to the axis | 0.15 mm | |
• perpendicular to the axis | 0.05 mm | |
– other engines: | ||
• parallel to the axis | 0.08mm | |
• perpendicular to the axis | 0 mm | |
Minimum allowable cylinder head height after machining: | ||
– 4-cylinder petrol engines | 97.8 mm | |
– 6-cylinder SOHC petrol engines | 89.5 mm | |
– 6-cylinder DOHC petrol engines | 135.5 mm | |
– diesel engines | 142.4 mm | |
Swirl chamber protrusion on diesel engines | 7.6 - 8.1 mm | |
Minimum protrusion of valves beyond the bottom plane of the cylinder head gasket when installing new valves and valve seats: | ||
– 4-cylinder petrol engines: | ||
• inlet valves | 1.7mm | |
• exhaust valves | 0.5 mm | |
– 6-cylinder SOHC petrol engines | 2.6L engines | 3.0L engines |
• inlet valves | 1.0 mm | 1.3 mm |
• exhaust valves | 0.8 mm | 1.4mm |
– 6-cylinder DOHC petrol engines | No data | |
– diesel engines: | ||
• inlet valves | 0.1 - 0.5 mm | |
• exhaust valves | 0.1 - 0.5 mm | |
Minimum valve protrusion beyond the bottom plane of the cylinder head gasket when installing machined valve seats and lapped valves: | ||
– 4-cylinder petrol engines: | ||
• inlet valves | 2.6 mm | |
• exhaust valves | 1.4mm | |
– 6-cylinder SOHC petrol engines | 2.6L engines | 3.0L engines |
• inlet valves | 1.7mm | 2.0 mm |
• exhaust valves | 1.5mm | 2.1mm |
– 6-cylinder DOHC petrol engines | No data | |
– diesel engines: | ||
• inlet valves | 0.7 mm | |
• exhaust valves | 0.7 mm |
Valves
Valve disc diameter: | |
4-cylinder petrol engines: | |
- inlet valves: | |
• 2.0 l engines | 42.90 - 43.10 mm |
• engines 2.3 l | 45.10 - 46.19 mm |
- exhaust valves | 38.90 - 39.10 mm |
SOHC 6-cylinder petrol engines: | |
– 2.6 l engines | |
• inlet valves | 40.0 mm |
• exhaust valves | 35.0 mm |
– 3.0 l engines | |
• inlet valves | 43.0 mm |
• exhaust valves | 39.0 mm |
6-cylinder DOHC gasoline engines | No data |
Diesel engines: | |
- inlet valves | 37.90 - 38.10 mm |
- exhaust valves | 34.90 - 35.10 mm |
Valve stem diameter: | |
– 4-cylinder petrol engines and 6-cylinder SOHC petrol engines: | |
• inlet valves | 7.955 - 7.970 mm |
• exhaust valves | 8.938 - 8.960 mm |
– 6-cylinder DOHC petrol engines | No data |
– diesel engines: | |
• inlet valves | 7.955 - 7.970 mm |
• exhaust valves | 8.945 - 8.960 mm |
Valve springs
Spring free length: | |
4-cylinder petrol engines | 49 mm |
SOHC 6-cylinder petrol engines | No data |
6-cylinder DOHC gasoline engines: | |
- with two springs: | |
• outer spring | 46.8 mm |
• internal spring | 47.6 mm |
- with one spring | 47.3 mm |
Diesel engines: | |
– with yellow/green or violet/green color coding | 50.8 mm |
– with yellow/blue or violet/blue color coding | 50.0 mm |
Cylinder block
Cylinder diameter: | |
4-cylinder petrol engines: | |
– 2.0 l engines: | |
• standard 0 | 88.998 - 89.008 mm |
• standard 1 | 89.009 - 89.018 mm |
• standard 2 | 89.019 - 89.028 mm |
• standard A | 89.000 - 89.006 mm |
• standard X | 89.007 - 89.012 mm |
• standard B | 89.013 - 89.018 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
– 2.3 l engines: | |
• standard 0 | 95.498 - 95.508 mm |
• standard 1 | 95.509 - 95.518 mm |
• standard 2 | 95.519 - 95.528 mm |
• standard A | 95.500 - 95.506 mm |
• standard X | 95.507 - 95.512 mm |
• standard B | 95.513 - 95.518 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
SOHC 6-cylinder petrol engines: | |
– 2.6 l engines: | |
• standard 0 | 82.898 - 82.908 mm |
• standard 1 | 82.908 - 82.918 mm |
• standard 2 | 82.918 - 82.928 mm |
• standard A | 82.900 - 82.906 mm |
• standard X | 82.906 - 82.912 mm |
• standard B | 82.912 - 82.918 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
– 3.0 l engines: | |
• standard 0 | 88.948 - 88.508 mm |
• standard 1 | 88.508 - 88.518 mm |
• standard 2 | 88.518 - 88.528 mm |
• standard A | 88.500 - 88.506 mm |
• standard X | 88.506 - 88.512 mm |
• standard B | 88.512 - 88.518 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
6-cylinder DOHC gasoline engines: | |
– 3.0 l engines: | |
• standard A | 88.500 - 88.506 mm |
• standard X | 88.506 - 88.512 mm |
• standard B | 88.512 - 88.518 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
– engines 2.8 and 3.2 l: | |
• standard A | 88.900 - 88.906 mm |
• standard X | 88.906 - 88.912 mm |
• standard B | 88.912 - 88.918 mm |
• increased by +0.25 mm | Dimensions as above +0.250 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
– diesel engines: | |
• standard A | 87.000 - 87.006 mm |
• standard X | 87.006 - 87.012 mm |
• standard B | 87.012 - 87.018 mm |
• increased by +0.7 mm | Dimensions as above +0.700 mm |
• maximum ovality of the cylinder: | |
– petrol engines | 0.05 mm |
– diesel engines | 0.07 mm |
Maximum taper of the cylinder: | |
– petrol engines | 0.05 mm |
– diesel engines | 0.07 mm |
Minimum engine block height: | |
– 4-cylinder petrol engines | 292.35 mm |
– 6-cylinder petrol engines | 281.95 mm |
– diesel engines | 299.62 mm |
Maximum flatness of the upper plane of the engine block: | |
– 4-cylinder petrol engines | No data |
– 6-cylinder petrol engines: | |
• parallel to the axis | 0.100 mm |
• perpendicular to the axis | 0.05 mm |
– diesel engines | 0.03mm |
Pistons
Piston diameter: | |
4-cylinder petrol engines: | |
– 2.0 l engines: | |
• standard 0 | 88.968 - 88.982 mm |
• standard 1 | 88.978 - 88.992 mm |
• standard 2 | 88.988 - 89.002 mm |
• standard A | 88.973 - 88.979 mm |
• standard X | 88.978 - 88.986 mm |
• standard B | 88.985 - 88.991 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
– 2.3 l engines: | |
• standard 0 | 95.469 - 95.481 mm |
• standard 1 | 95.479 - 95.491 mm |
• standard 2 | 95.489 - 95.501 mm |
• standard A | 95.473 - 95.479 mm |
• standard X | 95.478 - 95.486 mm |
• standard B | 95.485 - 95.491 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
SOHC 6-cylinder petrol engines: | |
– 2.6 l engines: | |
• standard 0 | 82.868 - 82.882 mm |
• standard 1 | 82.878 - 82.892 mm |
• standard 2 | 82.888 - 82.902 mm |
• standard A | 82.873 - 82.879 mm |
• standard X | 82.878 - 82.886 mm |
• standard B | 82.885 - 82.891 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
– 3.0 l engines: | |
• standard 0 | 88.469 - 88.481 mm |
• standard 1 | 88.479 - 88.491 mm |
• standard 2 | 88.489 - 88.501 mm |
• standard A | 88.473 - 88.479 mm |
• standard X | 88.478 - 88.486 mm |
• standard B | 88.485 - 88.491 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
6-cylinder DOHC gasoline engines: | |
– 3.0 l engines: | |
• standard A | 88.473 - 88.479 mm |
• standard X | 88.478 - 88.486 mm |
• standard B | 88.485 - 88.491mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
• increased by +1.0 mm | Dimensions as above +1,000 mm |
– engines 2.8 and 3.2 l: | |
• standard A | 88.478 - 88.879 mm |
• standard X | 88.878 - 88.886 mm |
• standard B | 88.885 - 88.891 mm |
• increased by +0.25 mm | Dimensions as above +0.250 mm |
• increased by +0.5 mm | Dimensions as above +0.500 mm |
Piston protrusion from the cylinder block of diesel engines: | |
– minimum | 0.735 mm |
– maximum | 0.965 mm |
Crankshaft
Axial play: | |
– 4-cylinder petrol engines | 0.300 mm |
– 6-cylinder SOHC petrol engines | 0.100 - 0.240 mm |
– 6-cylinder DOHC petrol engines | 0.100 - 0.250 mm |
– diesel engines | 0.300 mm |
The thickness of the thrust half rings for adjusting the axial play of the crankshaft | 2.15, 2.20, 2.25, 2.35, 2.40mm |
Crankshaft journal diameters: | |
– 4-cylinder petrol engines: | |
• nominal blue | 57.960 - 57.965 mm |
• nominal yellow | 57.955 - 57.960 mm |
• nominal red | 57.950 - 57.955 mm |
• nominal 1 blue | 57.945 - 57.950 mm |
• nominal 1 yellow | 57.940 - 57.945 mm |
• nominal 1 red | 57.935 - 57.940 mm |
• reduced 1 | 57.705 - 57.715 mm |
• reduced 2 | 57.455 - 57.465 mm |
• reduced 3 | 57.205 - 57.215 mm |
• reduced 4 | 56.955 - 56.965 mm |
– 6-cylinder SOHC petrol engines | No data |
– 6-cylinder DOHC gasoline engines: | |
• nominal blue | 57.960 - 57.965 mm |
• nominal yellow | 57.955 - 57.960 mm |
• nominal red | 57.950 - 57.955 mm |
• nominal 1 white | 57.945 - 57.950 mm |
• nominal 1 purple | 57.940 - 57.945 mm |
• reduced 1 | 57.705 - 57.715 mm |
• reduced 2 | 57.455 - 57.465 mm |
• reduced 3 | 57.205 - 57.215 mm |
• reduced 4 | 56.955 - 56.965 mm |
– diesel engines: | |
• nominal | 57.959 - 57.965 mm |
• reduced 1 | 57.700 - 57.715 mm |
• reduced 2 | 57.450 - 57.465 mm |
• reduced 3 | 57.200 - 57.215 mm |
• reduced 4 | 56.959 - 56.965 mm |
Diameters of connecting rod journals of the crankshaft: | |
– 4-cylinder petrol engines: | |
• nominal | 47.955 - 47.965 mm |
• reduced 1 | 47.705 - 47.715 mm |
• reduced 2 | 47.455 - 47.465 mm |
• reduced 3 | 47.205 - 47.215 mm |
• reduced 4 | 46.955 - 46.965 mm |
– 6-cylinder DOHC gasoline engines: | |
• nominal | 47.955 - 47.965 mm |
• nominal 1 | 47.945 - 47.955 mm |
• reduced 1 | 47.700 - 47.715 mm |
• reduced 2 | 47.450 - 47.465 mm |
• reduced 3 | 47.200 - 47.215 mm |
• reduced 4 | 46.950 - 46.955 mm |
– diesel engines: | |
• nominal | 47.950 - 47.965 mm |
• reduced 1 | 47.700 - 47.715 mm |
• reduced 2 | 47.450 – 47.650 mm |
• reduced 3 | 47.200 - 47.215 mm |
• reduced 4 | 46.950 - 46.965 mm |
Operating clearance of main bearings: | |
– 4-cylinder petrol engines | 0.070 mm |
– 6-cylinder SOHC petrol engines | 0.030 - 0.050 mm |
– 6-cylinder DOHC petrol engines | 0.030 - 0.045 mm |
– diesel engines | 0.080 mm |
Working clearance of connecting rod bearings: | |
– 4-cylinder petrol engines | 0.070 mm |
– 6-cylinder SOHC petrol engines | 0.030 - 0.060 mm |
– 6-cylinder DOHC petrol engines | 0.020 - 0.050 mm |
– diesel engines | 0.080 mm |
Piston rings
Piston ring clearance: | |
– 4-cylinder petrol engines: | |
• rather compression ring | 0.30 - 1.00 mm |
• middle compression ring | 0.25 - 0.80 mm |
• oil scraper ring | 0.25 - 0.80 mm |
– 6-cylinder petrol engines: | |
• rather compression ring | 0.15 - 0.50 mm |
• middle compression ring | 0.20 - 0.40 mm |
• oil scraper ring | 0.10 - 0.45 mm |
– diesel engines: | |
• rather compression ring | 0.09 - 0.20 mm |
• middle compression ring | 0.15 - 0.15 mm |
• oil scraper ring | 0.03 - 0.10 mm |
Main bearing cap bolts
Maximum length: | |
– 6-cylinder DOHC petrol engines | 63.8 mm |
Connecting rod bearing cap bolts
Minimum Diameter: | |
– 4-cylinder petrol engines | 8.0 mm |
Maximum length: | |
– all engines except 4-cylinder petrol engines | 52.9 mm |
Tightening torques
4-cylinder petrol engines | See specifications in chapter 3 |
SOHC 6-cylinder petrol engines | See specifications in chapter 4 |
6-cylinder DOHC gasoline engines | See specifications in chapter 5 |
Diesel engines | See specifications in chapter 6 |