Page 2409 of 3051
Cylinder BlockNLEM0150Unit: mm (in)
SEM008D
SEM686DB
Surface flatnessStandard Less than 0.03 (0.0012)
Limit 0.10 (0.0039)
Cylinder bore inner diameterStandardGrade No. 1 86.000 - 86.010 (3.3858 - 3.3862)
Grade No. 2 86.010 - 86.020 (3.3862 - 3.3866)
Grade No. 3 86.020 - 86.030 (3.3866 - 3.3870)
Wear limit 0.20 (0.0079)
Out-of-round (X þ Y)Less than 0.015 (0.0006)
Taper (A þ B and A þ C)Less than 0.010 (0.0004)
Difference in inner diameter between cylin-
dersLimit Less than 0.05 (0.0020)
Main journal inner diameterGrade No. 0 58.944 - 58.950 (2.3206 - 2.3209)
Grade No. 1 58.950 - 58.956 (2.3209 - 2.3211)
Grade No. 2 58.956 - 58.962 (2.3211 - 2.3213)
Grade No. 3 58.962 - 58.968 (2.3213 - 2.3216)
SERVICE DATA AND SPECIFICATIONS (SDS)SR
Cylinder Block
EM-152
Page 2410 of 3051

Piston, Piston Ring and Piston Pin=NLEM0151PISTONNLEM0151S01Unit: mm (in)
SEM086G
Piston skirt diameter ªAº
StandardGrade No. 1 85.980 - 85.990 (3.3850 - 3.3854)
Grade No. 2 85.990 - 86.000 (3.3854 - 3.3858)
Grade No. 3 86.000 - 86.010 (3.3858 - 3.3862)
0.20 (0.0079) oversize (Service) 86.180 - 86.210 (3.3929 - 3.3941)
ªaº dimension45.0 (1.772)
Piston clearance to cylinder block 0.010 - 0.030 (0.0004 - 0.0012)
Piston pin hole diameter21.993 - 22.005 (0.8659 - 0.8663)
PISTON RINGNLEM0151S02
Side clearanceTo pStandard 0.04 - 0.08 (0.0016 - 0.0031)
Limit 0.1 (0.004)
2ndStandard 0.03 - 0.07 (0.0012 - 0.0028)
Limit 0.1 (0.004)
OilStandard 0.065 - 0.135 (0.0026 - 0.0053)
Limit 0.15 (0.0059)
Ring end gapTo pStandard 0.20 - 0.39 (0.0079 - 0.0154)
Limit 1.00 (0.0349)
2ndStandard 0.35 - 0.59 (0.0138 - 0.0232)
Limit 1.00 (0.0349)
OilStandard 0.20 - 0.69 (0.0079 - 0.0272)
Limit 1.00 (0.0349)
PISTON PINNLEM0151S03Unit: mm (in)
Piston pin outer diameter21.989 - 22.001 (0.8657 - 0.8622)
Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing clearanceStandard 0.005 - 0.017 (0.0002 - 0.0007)
Limit 0.023 (0.0009)
*Values measured at ambient temperature of 20ÉC (68ÉF)
SERVICE DATA AND SPECIFICATIONS (SDS)SR
Piston, Piston Ring and Piston Pin
EM-153
Page 2411 of 3051
Connecting RodNLEM0152Unit: mm (in)
Center distance136.25 - 136.35 (5.3642 - 5.3681)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod small end inner diameter 24.980 - 25.000 (0.9835 - 0.9843)
Piston pin bushing inner diameter* 22.000 - 22.012 (0.8661 - 0.8666)
Connecting rod big end inner diameter 51.000 - 51.013 (2.0079 - 2.0084)
Side clearanceStandard 0.20 - 0.35 (0.0079 - 0.0138)
Limit 0.5 (0.020)
*After installing in connecting rod
SERVICE DATA AND SPECIFICATIONS (SDS)SR
Connecting Rod
EM-154
Page 2412 of 3051
CrankshaftNLEM0153Unit: mm (in)
Main journal dia. ªDmºGrade No. 0 54.974 - 54.980(2.1643 - 2.1646)
Grade No. 1 54.968 - 54.974 (2.1641 - 2.1643)
Grade No. 2 54.962 - 54.968 (2.1639 - 2.1641)
Grade No. 3 54.956 - 54.962 (2.1636 - 2.1639)
Pin journal dia. ªDpºGrade No. 0 47.968 - 47.974 (1.8885 - 1.8887)
Grade No. 1 47.962 - 47.968 (1.8883 - 1.8885)
Grade No. 2 47.956 - 47.962 (1.8880 - 1.8883)
Center distance ªrº42.96 - 43.04 (1.6913 - 1.6945)
Out-of-round (X þ Y)
StandardMain journal Less than 0.005 (0.0002)
Pin journal Less than 0.003 (0.0001)
Taper (A þ B)
StandardMain journal Less than 0.005 (0.0002)
Pin journal Less than 0.0025 (0.0001)
Runout [TIR]Standard Less than 0.025 (0.0010)
Limit Less than 0.05 (0.0020)
Free end playStandard 0.10 - 0.26 (0.0039 - 0.0102)
Limit 0.30 (0.0118)
SEM954C
EM715
SERVICE DATA AND SPECIFICATIONS (SDS)SR
Crankshaft
EM-155
Page 2413 of 3051

Main BearingNLEM0154
SEM685D
STANDARDNLEM0154S01Unit: mm (in)
Grade number Thickness ªTº Width ªWº Identification color (mark)
0 1.977 - 1.980 (0.0778 - 0.0780)
18.9 - 19.1 (0.744 - 0.752)Black (A)
1 1.980 - 1.983 (0.0780 - 0.0781) Red (B)
2 1.983 - 1.986 (0.0781 - 0.0782) Green (C)
3 1.986 - 1.989 (0.0782 - 0.0783) Yellow (D)
4 1.989 - 1.992 (0.0783 - 0.0784) Blue (E)
5 1.992 - 1.995 (0.0784 - 0.0785) Pink (F)
6 1.995 - 1.998 (0.0785 - 0.0787) White (G)
UNDERSIZENLEM0154S02Unit: mm (in)
Undersize Thickness ªTº Main journal diameter ªDmº
0.25 (0.0098) 2.109 - 2.117 (0.0830 - 0.0833)Grind so that bearing clearance is the specified
value.
Connecting Rod BearingNLEM0155STANDARD SIZENLEM0155S01Unit: mm (in)
Grade number Thickness ªTº Width ªWº Identification color (mark)
0 1.500 - 1.503 (0.0591 - 0.0592)
16.9 - 17.1 (0.665 - 0.673)Black or Yellow (A)
1 1.503 - 1.506 (0.0592 - 0.0593) Brown or Red (B)
2 1.506 - 1.509 (0.0593 - 0.0594) Green or Blue (C)
UNDERSIZENLEM0155S02Unit: mm (in)
Undersize Thickness ªTº Crank pin journal diameter ªDpº
0.08 (0.0031) 1.541 - 1.549 (0.0607 - 0.0610)
Grind so that bearing clearance is the specified
value. 0.12 (0.0047) 1.561 - 1.569 (0.0615 - 0.0618)
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)
SERVICE DATA AND SPECIFICATIONS (SDS)SR
Main Bearing
EM-156
Page 2414 of 3051
Bearing ClearanceNLEM0156Unit: mm (in)
Main bearing clearanceStandard 0.004 - 0.022 (0.0002 - 0.0009)
Limit 0.05 (0.020)
Connecting rod bearing clearanceStandard 0.020 - 0.045 (0.0008 - 0.0018)
Limit 0.065 (0.0026)
Miscellaneous ComponentsNLEM0157Unit: mm (in)
Camshaft sprocket runout limit [TIR] 0.25 (0.0098)
Drive plate runout limit [TIR]0.2 (0.008)
SERVICE DATA AND SPECIFICATIONS (SDS)SR
Bearing Clearance
EM-157
Page 2415 of 3051

Parts Requiring Angular TighteningNLEM0047+Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
+Do not use a torque value for final tightening.
+The torque value for these parts are for a preliminary step.
+Ensure thread and seat surfaces are clean and coated with
engine oil.
SEM164F
Liquid Gasket Application ProcedureNLEM00481.Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2.Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+Be sure liquid gasket diameter is as specified.
AEM080
3.Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4.Assembly should be done within 5 minutes after coating.
5.Wait at least 30 minutes before refilling engine oil and
engine coolant.
PRECAUTIONSYD
Parts Requiring Angular Tightening
EM-158
Page 2416 of 3051
Special Service ToolsNLEM0049
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
Base
NT042
Disassembling and assembling
KV10106500
Engine stand shaft
NT028
KV11105900
Engine sub-attachment
NT799
KV10115900 has been replaced with
KV10106500.
KV10115600
Valve oil seal drift
NT603
Installing valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1 KV10116100
Valve oil seal puller
adapter
NT605
Removing valve oil seal
KV11103000
Injection pump drive gear
puller
NT676
PREPARATIONYD
Special Service Tools
EM-159