Cylinder Block

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

CYLINDER BLOCK - SERVICE DATA

Connecting rod	Thrust clearance	Standard		0.15 to 0.55 mm (0.00591 to 0.0217 in.)
		Maximum		0.70 mm (0.0276 in.)
	Oil clearance	Standard		0.025 to 0.050 mm (0.000984 to 0.00197 in.)
		Maximum		0.070 mm (0.00276 in.)
	Standard sized bearing center wall thickness	Mark 2		1.489 to 1.492 mm (0.0586 to 0.0587 in.)
		Mark 3		1.492 to 1.495 mm (0.0587 to 0.0589 in.)
		Mark 4		1.495 to 1.498 mm (0.0589 to 0.0590 in.)
		Mark 5		1.498 to 1.501 mm (0.0590 to 0.0591 in.)
		Mark 6		1.501 to 1.504 mm (0.0591 to 0.0592 in.)
		Mark 7		1.504 to 1.507 mm (0.0592 to 0.0593 in.)
	Big end inside diameter	Mark 1		59.000 to 59.006 mm (2.32283 to 2.32306 in.)
		Mark 2		59.007 to 59.012 mm (2.32311 to 2.32330 in.)
		Mark 3		59.013 to 59.018 mm (2.32334 to 2.32354 in.)
		Mark 4		59.019 to 59.024 mm (2.32358 to 2.32377 in.)
	Bend	Maximum		0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
	Twist	Maximum		0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Crankshaft pin	Diameter	Mark 1		55.995 to 56.000 mm (2.20452 to 2.20472 in.)
		Mark 2		55.989 to 55.994 mm (2.20429 to 2.20448 in.)
		Mark 3		55.982 to 55.998 mm (2.20401 2.20464 in.)
Cylinder block	Warpage	Maximum		0.07 mm (0.00276 in.)
	Cylinder bore	Standard		94.000 to 94.012 mm (3.700 to 3.701 in.)
		Maximum		94.200 mm (3.709 in.)
Piston ring	Groove clearance	No. 1		0.020 to 0.070 mm (0.000787 to 0.00276 in.)
		No. 2		0.020 to 0.060 mm (0.000787 to 0.00236 in.)
		Oil		0.020 to 0.070 mm (0.000787 to 0.00276 in.)
	End gap	Standard	No. 1	0.25 to 0.35 mm (0.00984 to 0.0138 in.)
			No. 2	0.40 to 0.50 mm (0.0157 to 0.0197 in.)
			Oil	0.10 to 0.40 mm (0.00394 to 0.0157 in.)
		Maximum	No. 1	0.42 mm (0.0165 in.)
			No. 2	0.55 mm (0.0217 in.)
			Oil	0.45 mm (0.0177 in.)
Piston	Diameter	Standard		93.940 to 93.950 mm (3.6984 to 3.6988 in.)
		Minimum		93.815 mm (3.6935 in.)
	Oil clearance	Standard		0.050 to 0.072 mm (0.00197 to 0.00283 in.)
		Maximum		0.385 mm (0.0152 in.)
Piston pin	Hole inside diameter	Mark A		21.998 to 22.001 mm (0.86606 to 0.86618 in.)
		Mark B		22.002 to 22.004 mm (0.86622 to 0.86630 in.)
		Mark C		22.005 to 22.007 mm (0.86634 to 0.86642 in.)
	Diameter	Mark A		21.997 to 22.000 mm (0.86602 to 0.86614 in.)
		Mark B		22.001 to 22.003 mm (0.86618 to 0.86626 in.)
		Mark C		22.004 to 22.006 mm (0.86630 to 0.86638 in.)
	Oil clearance	Standard		-0.002 to 0.004 mm (-0.0000787 to 0.000157 in.)
		Maximum		0.015 mm (0.000591 in.)
Connecting rod bush	Inside diameter	Mark A		22.005 to 22.008 mm (0.86634 to 0.86645 in.)
		Mark B		22.009 to 22.011 mm (0.86649 to 0.86657 in.)
		Mark C		22.012 to 22.014 mm (0.86661 to 0.86669 in.)
	Oil clearance	Standard		0.005 to 0.011 mm (0.000197 to 0.000433 in.)
		Maximum		0.03 mm (0.00118 in.)
Crankshaft	Thrust clearance	Standard		0.020 to 0.220 mm (0.000787 to 0.00866 in.)
		Maximum		0.30 mm (0.0118 in.)
	Thrust washer thickness	Standard		2.44 to 2.49 mm (0.0961 to 0.0980 in.)
	Circle runout	Maximum		0.06 mm (0.00236 in.)
	Main journal	Diameter	Standard	66.988 to 67.000 mm (2.6373 to 2.6378 in.)
		Taper and out-of-round	Maximum	0.02 mm (0.000787 in.)
	Crank pin	Diameter	Standard	55.982 to 56.000 mm (2.2040 to 2.2047 in.)
		Taper and out-of-round	Maximum	0.02 mm (0.000787 in.)
	Oil clearance	No. 1 and No. 5 journal	Standard	0.017 to 0.030 mm (0.000669 to 0.00118 in.)
			Maximum	0.050 mm (0.00197 in.)
		Other journal	Standard	0.024 to 0.037 mm (0.000945 to 0.00146 in.)
			Maximum	0.060 mm (0.00236 in.)
Crankshaft journal bearing center wall thickness No. 1 and No. 5 journal	Upper bearing	00 to 02	4	2.501 to 2.504 (0.0985 to 0.0986 in.)
		03 to 05	5	2.504 to 2.507 (0.0986 to 0.0987 in.)
		06 to 08	5	2.504 to 2.507 (0.0986 to 0.0987 in.)
		09 to 11	6	2.507 to 2.510 (0.0987 to 0.0988 in.)
		12 to 14	6	2.507 to 2.510 (0.0987 to 0.0988 in.)
		15 to 17	7	2.510 to 2.513 (0.0988 to 0.0989 in.)
		18 to 20	7	2.510 to 2.513 (0.0988 to 0.0989 in.)
		21 to 23	8	2.513 to 2.516 (0.0989 to 0.0991 in.)
		24 to 26	8	2.513 to 2.516 (0.0989 to 0.0991 in.)
		27 to 28	9	2.516 to 2.519 (0.0991 to 0.0992 in.)
	Lower bearing	00 to 02	5	2.488 to 2.491 (0.0980 to 0.0981 in.)
		03 to 05	5	2.488 to 2.491 (0.0980 to 0.0981 in.)
		06 to 08	6	2.491 to 2.494 (0.0981 to 0.0982 in.)
		09 to 11	6	2.491 to 2.494 (0.0981 to 0.0982 in.)
		12 to 14	7	2.494 to 2.497 (0.0982 to 0.0983 in.)
		15 to 17	7	2.494 to 2.497 (0.0982 to 0.0983 in.)
		18 to 20	8	2.497 to 2.500 (0.0983 to 0.0984 in.)
		21 to 23	8	2.497 to 2.500 (0.0983 to 0.0984 in.).
		24 to 26	9	2.500 to 2.503 (0.0984 to 0.0985 in.)
		27 to 28	9	2.500 to 2.503 (0.0984 to 0.0985 in.)
Bearing center wall thickness Other journal	Upper bearing	00 to 02	3	2.482 to 2.485 (0.0977 to 0.0978 in.)
		03 to 05	4	2.485 to 2.488 (0.0978 to 0.0980 in.)
		06 to 08	4	2.485 to 2.488 (0.0978 to 0.0980 in.)
		09 to 11	5	2.488 to 2.491 (0.0980 to 0.0981 in.)
		12 to 14	5	2.488 to 2.491 (0.0980 to 0.0981 in.)
		15 to 17	6	2.491 to 2.494 (0.0981 to 0.0982 in.)
		18 to 20	6	2.491 to 2.494 (0.0981 to 0.0982 in.)
		21 to 23	7	2.494 to 2.497 (0.0982 to 0.0983 in.)
		24 to 26	7	2.494 to 2.497 (0.0982 to 0.0983 in.)
		27 to 28	8	2.497 to 2.500 (0.0983 to 0.0984 in.)
	Lower bearing	00 to 02	4	2.501 to 2.504 (0.0985 to 0.0986 in.)
		03 to 05	4	2.501 to 2.504 (0.0985 to 0.0986 in.)
		06 to 08	5	2.504 to 2.507 (0.0986 to 0.0987 in.)
		09 to 11	5	2.504 to 2.507 (0.0986 to 0.0987 in.)
		12 to 14	6	2.507 to 2.510 (0.0987 to 0.0988 in.)
		15 to 17	6	2.507 to 2.510 (0.0987 to 0.0988 in.)
		18 to 20	7	2.510 to 2.513 (0.0988 to 0.0989 in.)
		21 to 23	7	2.510 to 2.513 (0.0988 to 0.0989 in.)
		24 to 26	8	2.513 to 2.516 (0.0989 to 0.0991 in.)
		27 to 28	8	2.513 to 2.516 (0.0989 to 0.0991 in.)
Connecting rod bolt	Diameter	Standard		8.5 to 8.6 mm (0.335 to 0.339 in.)
		Minimum		8.3 mm (0.327 in.)
Crankshaft bearing cap set bolt	Diameter	Bolt A	Standard	10.5 to 11.0 mm (0.413 to 0.433 in.)
			Minimum	10.4 mm (0.409 in.)
		Bolt B	Standard	9.5 to 10.0 mm (0.374 to 0.394 in.)
			Minimum	9.4 mm (0.370 in.)
Straight pin	Protrusion height	A		23 mm (0.906 in.)
		B		11 mm (0.433 in.)
		C		9 mm (0.354 in.)
		D		6 mm (0.236 in.)
Crankshaft bearing	Bearing cap's edge and the lower bearing's edge	Dimension A - B or B - A		0 to 0.7 mm (0 to 0.0276 in.)
Connecting rod bearing	connecting rod's and bearing cap's edges	Dimension A - B or B - A		0 to 0.7 mm (0 to 0.0276 in.)

ENGINE UNIT

ENGINE UNIT - SERVICE DATA

Cylinder head set bolt	Outside diameter	Standard		10.85 to 11.00 mm (0.427 to 0.433 in.)
		Minimum		10.6 mm (0.417 in.)
Camshaft	Circle runout	Maximum		0.04 mm (0.00157 in.)
	Cam lobe height	Intake	Standard	44.291 to 44.441 mm (1.744 to 1.750 in.)
			Minimum	44.241 mm (1.742 in.)
		Exhaust	Standard	44.196 to 44.346 mm (1.740 to 1.746 in.)
			Minimum	44.146 mm (1.738 in.)
	Journal diameter	No. 1 journal	Standard	29.956 to 29.970 mm (1.1793 to 1.1799 in.)
		Other journal		25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Timing chain	No. 1 chain	Chain elongation	Maximum	136.9 mm (5.39 in.)
	No. 2 chain			137.6 mm (5.42 in.)
Sprocket diameter (w/ chain)	Crankshaft timing sprocket RH	Minimum		61.4 mm (2.42 in.)
	Crankshaft timing sprocket LH			61.4 mm (2.42 in.)
No. 2 chain tensioner	Depth	Maximum		0.9 mm (0.0354 in.)
No. 3 chain tensioner				0.9 mm (0.0354 in.)
Chain tensioner slipper				1.0 mm (0.0394 in.)
No. 1 chain vibration damper				1.0 mm (0.0394 in.)
Exhaust manifold	Warpage			0.7 mm (0.0276 in.)
Ring pin	Protrusion height	A		7.5 to 8.5 mm (0.295 to 0.335 in.)
		B		3.6 to 4.6 mm (0.142 to 0.181 in.)