New Product Information

New Product Information
The purpose of New Product Information is to highlight or indicate important product changes from the previous model year.
Changes may include one or more of the following items:
^ Torque values and/or fastener tightening strategies
^ Changed engine specifications
^ New sealants and/or adhesives
^ Disassembly and assembly procedure revisions
^ Engine mechanical diagnostic procedure revisions
^ New special tools required
^ A component comparison from the previous year

Torque Values and/or Fastener Tightening Strategies
The fastener tightening specifications for engine unit repairs have not changed for 2003.

Changed Engine Specifications
There are early and late design engine mechanical specifications for connecting rod bore diameter - pin end, piston pin bore diameter and piston pin diameter. There are changes in drill depth and tap depth to the engine block deck face holes for the cylinder head bolts.

New Sealants and/or Adhesives
The sealants and adhesives for engine unit repair have not changed for 2003.

Disassembly and Assembly Procedure Revisions
The Lubrication System Priming Procedure has been replaced by the Lubrication Preluber Procedure. A new tool J45299 has been developed to prime the engine with new clean engine oil. There are early and late design crankshaft rear oil seals. The early design crankshaft rear oil seal requires the use of the installlation tool J42842. in order to set the correct depth. The late design crankshaft rear oil seal requires the use of a new installation tool J44642 in order to set the correct depth.

Engine Mechanical Diagnostic Procedure Revisions
Additional engine coolant leakage diagnostics have been added.

New Special Tools Required
*A new tool J45299 has been developed to prime the engine with new clean engine oil. *Starting in model year 2003 the bushing used in the fixture plate has been replaced by J42385-2002. For model year 2000 through 2002 use J42385-302.

*There are early and late design crankshaft rear oil seals. The early design crankshaft rear oil seal requires the use of the installation tool J42842 in order to set the correct depth. The late design crankshaft rear oil seal requires the use of a new installation tool J44642 in order to set the correct depth.

A Component Comparison from the Previous Year
*The oil filter adapter has been revised. An oil filter adapter gasket replaces the previously used O-rings. *The lower crankcase has been revised. The oil filter adapter mounting area on the lower crankcase has been modified to accommodate the changes made to the oil filter adapter and the sealing of the oil filter adapter gasket.

Notice: Do not mix early and late design components. Improper clamp loads will occur if cylinder head bolts are tightened using a mixture of early and late design components. Improper clamp loads will occur if cylinder head bolts are tightened using a mixture of early and late design components. Damage will occur to the powertrain if mixed components are used.

*The engine block holes in the engine block deck faces for the M11 cylinder head bolts have decreased in depth, they are drilled and tapped approximately 7 mm (0.276 in) shallower. *The bosses in the cylinder heads for the M11 cylinder head bolts have increased in height, they are approximately 7 mm (0.276 in ) higher.

Notice: Do not mix early and late design components. The internal balance of the engine will be affected if early and late design components are used together. Damage will occur to the powertrain if mixed components are used.

*There are early and late design crankshaft, connecting rods, pistons and pistons pins. The early and late design components must not be interchanged.

Notice: The proper installation tool must be used with the proper component. Early and late design components are installed to different depths. Damage and/or leakage can occur if the improper installation tool is used.

*There are early and late design crankshaft rear oil seals. The early design crankshaft rear oil seal requires the use of the installatio tool J42842 in order to set the correct depth. The late design crankshaft rear oil seal requires the use of a new installation tool J44642. in order to set the correct depth.