System Specifications

Connecting Rod Bolt/Screw - First Pass 20 Nm (15 ft. lbs.)
Connecting Rod Bolt/Screw - Final Pass 75 degrees
Crankshaft Balancer Bolt/Screw - Installation Pass to Ensure the Balancer is Completely Installed 330 Nm (240 ft. lbs.)
Crankshaft Balancer Bolt/Screw
First Pass - Install a NEW Bolt/Screw After the Installation Pass and Tighten as Described in the First and Final Passes 50 Nm (37 ft. lbs.)
Crankshaft Balancer Bolt/Screw - Final Pass 140 degrees
Crankshaft Bearing Cap M10 Bolt/Screw
First Pass in Sequence 20 Nm (15 ft. lbs.)
Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap M10 Studs
First Pass in Sequence 20 Nm (15 ft. lbs.)
Final Pass in Sequence 51 degrees
Crankshaft Bearing Cap M8 Bolt/Screw 25 Nm (18 ft. lbs.)
Crankshaft Oil Deflector Nuts 25 Nm (18 ft. lbs.)
Crankshaft Position (CKP) Sensor Bolt/Screw 25 Nm (18 ft. lbs.)
Engine Block Coolant Drain Hole Plug 60 Nm (44 ft. lbs.)
Engine Block Coolant Heater 50 Nm (37 ft. lbs.)
Engine Block Oil Gallery Plug 60 Nm (44 ft. lbs.)
Bore 96.0 - 96.018 mm (3.779 - 3.78 in)
Stroke 92.0 mm (3.622 in)
Crankshaft
Crankshaft Main Bearing Bore Diameter 69.871 - 69.889 mm (2.75 - 2.751 in)
Crankshaft Main Bearing Bore Out-of-Round 0.006 mm (0.0002 in)
Cylinder Bore Diameter 96.0-96.018 mm (3.779 - 3.78 in)
Connecting Rod
Connecting Rod Bearing Clearance
Production 0.023 - 0.065 mm (0.0009 - 0.0025 in)
Service 0.023 - 0.076 mm (0.0009 - 0.003 in)
Connecting Rod Bore Diameter - Bearing End 56.505 - 56.525 mm (2.224 - 2.225 in)
Connecting Rod Bore Out-of-Round - Bearing End
Production 0.004 - 0.008 mm (0.00015 - 0.0003 in)
Service 0.004 - 0.008 mm (0.00015 - 0.0003 in)
Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 in)
Crankshaft
Connecting Rod Journal Diameter
Production 53.318 - 53.338 mm (2.0991 - 2.0999 in)
Service 53.308 mm (2.0987 in)
Connecting Rod Journal Out-of-Round
Production 0.005 mm (0.0002 in)
Service 0.01 mm (0.0004 in)
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length -
Production 0.005 mm (0.0002 in)
Service 0.02 mm (0.00078 in)
Crankshaft End Play 0.04 - 0.2 mm (0.0015 - 0.0078 in)
Crankshaft Main Bearing Clearance -
Production 0.02 - 0.052 mm (0.0008 - 0.0021 in)
Service 0.02 - 0.065 mm (0.0008 - 0.0025 in)
Crankshaft Main Journal Diameter
Production 64.992 - 65.008 mm (2.558 - 2.559 in)
Service 64.992 mm (2.558 in)
Crankshaft Main Journal Out-of-Round
Production 0.003 mm (0.000118 in)
Service 0.008 mm (0.0003 in)
Crankshaft Main Journal Taper
Production 0.01 mm (0.0004 in)
Service 0.02 mm (0.00078 in)
Crankshaft Rear Flange Runout 0.05 mm (0.002 in)
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below Tooth Diameter 0.7 mm (0.028 in)
Crankshaft Thrust Surface
Production 26.14 - 26.22 mm (1.029 - 1.0315 in)
Service 26.22 mm (1.0315 in)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 in)
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore
Production 0.23 - 0.44 mm (0.009 - 0.017 in)
Service 0.23 - 0.5 mm (0.009 - 0.0196 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore
Production 0.44 - 0.7 mm (0.017 - 0.027 in)
Service 0.44 - 0.76 mm (0.0173 - 0.03 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore -
Production 0.18 - 0.75 mm (0.007 - 0.029 in)
Service 0.18 - 0.81 mm (0.007 - 0.032 in)
Piston Ring-to-Groove Clearance - First Compression Ring
Production 0.04 - 0.085 mm (0.00157 - 0.00335 in)
Service 0.04 - 0.085 mm (0.00157 - 0.00335 in)
Piston Ring-to-Groove Clearance - Second Compression Ring
Production 0.04 - 0.078 mm (0.00157 - 0.0031 in)
Service 0.04 - 0.078 mm (0.00157 - 0.0031 in)
Piston Ring-to-Groove Clearance - Oil Control Ring
Production 0.012 - 0.2 mm (0.0005 - 0.0078 in)
Service 0.012 - 0.2 mm (0.0005 - 0.0078 in)
Pistons and Pins
Pin - Piston Pin Clearance-to-Piston Pin Bore
Production 0.002 - 0.01 mm (0.00008 - 0.0004 in)
Service 0.002 - 0.015 mm (0.00008 - 0.0006 in)
Pin - Piston Pin Diameter 23.952 - 23.955 mm (0.943 - 0.943 in)
Pin - Piston Pin Fit in Connecting Rod Bore
Production 0.007 - 0.02 mm (0.00027 - 0.00078 in)
Service 0.007 - 0.022 mm (0.00027 - 0.00086 in)
Piston - Piston Diameter - Measured Over Skirt Coating 96.002 - 96.036 mm (3.779 - 3.78 in)
Piston - Piston-to-Bore Clearance
Production -0.036 to +0.016 mm (-0.0014 to +0.0006 in)
Service Limit with Skirt Coating Worn Off 0.071 mm (0.0028 in)