System Specifications

Cylinder Bore Diameter 41 mm ((1.610 inch)
Below Deck Face 92.992-93.008 mm (3.6611-3.6617 inch)
Cylinder Bore Out-of-Round Production 0.010 mm (0.0004 inch)
Service 0.100 mm (0.0039 inch)
Cylinder Bore Taper Production 0.010 mm (0.0004 inch)
Service 0.100 mm (0.0039 inch)
Cylinder Head Deck Height 224.55 mm (8.8406 inch)
Cylinder Head Deck Surface Flatness 0.100 mm (0.0039 inch)
Surface Flatness - Block Deck 0.050 mm (0.0020 inch)
Surface Flatness - Exhaust Manifold Deck 0.220 mm (0.0087 inch)
Surface Flatness - Intake Manifold Deck 0.220 mm (0.0087 inch)
Crankshaft Main Journal Diameter 64.350-64.366 mm (2.5335-2.5341 inch)
Crankshaft Main Journal Out-of-Round 0.005 mm (0.0002 inch)
Crankshaft Main Journal Taper 0.005 mm (0.0002 inch)
Crankshaft Main Bearing Clearance Production 0.0.150-0.0550 mm (0.0006-0.0022 inch)
Service 0.0150-0.0635 mm (0.0006-0.0025 inch)
Crankshaft Main Journal Thrust Wall Runout 0.040 mm (0.0016 inch)
Crankshaft Main Journal Thrust Wall Square 0.010 mm (0.0004 inch)
Crankshaft Main Journal Width, #1, #2, #4, #5 24.540-24.660 mm (0.9661-0.9709 inch)
Crankshaft Main Journal Width, Thrust #3 25.150-25.250 mm (0.9902-0.9941 inch)
Connecting Rod Side Clearance 0.200-0.500 mm (0.0079-0.0197 inch)
Connecting Rod Bore Diameter - Bearing End 57.136-57.152 mm (2.2495-2.2501 inch)
Connecting Rod Bore Diameter - Pin End 23.002-23.014 mm (0.9056-0.9061 inch)
Connecting Rod Bore Out-of-Round - Bearing End 0.006 mm (0.0002 inch)
Connecting Rod Bore Out-of-Round - Pin End 0.005 mm (0.0002 inch)
Connecting Rod Bearing Clearance Production and Service 0.0250-0.0760 mm (0.0010-0.0030 inch)
Piston Diameter 42 mm (1.6353 inch)
Piston to Bore Clearance 0.020-0.051 mm (0.0008-0.0020 inch)
Piston Ring Groove Inside Diameter
First Compression Ring 84.750-85.000 mm (3.3366-3.3464 inch)
Second Compression Ring 83.400-83.650 mm (3.2835-3.2933 inch)
Oil Control Ring 85.670-85.920 mm (3.3728-3.3827 inch)
Piston Ring Groove Width
First Compression Ring 1.230-1.255 mm (0.0494 inch)
Second Compression Ring 1.530-1.555 mm (0.0602-0.0612 inch)
Oil Control Ring 2.530-2.555 mm (0.0996-0.1006 inch)
Piston Ring End Gap
First Compression Ring 0.250-0.400 mm (0.0098-0.0157 inch)
Second Compression Ring 0.350-0.050 mm (0.0138-0.0020 inch)
Oil Control Fling 0.250-0.760 mm (0.0098-0.0299 inch)
Piston Ring to Groove Clearance
First Compression Ring 0.040-0.095 mm (0.00 16-0.0037 inch)
Second Compression Ring 0.040-0.095 mm (0.0016-0.0037 inch)

Crankshaft Balancer Bolt
First Pass
Crankshaft Balancer Bolt 50 Nm (37 ft. lbs.)
Final Pass
Tighten the crankshaft balancer bolt an additional 120 degrees using the J 45059





Crankshaft Main Bearing
1. Tighten the lower crankcase bolts in proper sequence.
1.1. First Pass
^ Tighten the lower crankcase bearing bolts (1 through 20) to 20 Nm (15 ft. lbs.) in the proper sequence.
1.2. Final Pass
^ Tighten the lower crankcase bolts (1 through 20) an additional 65 degrees in the proper sequence using the J 45059.





2. Tighten the upper-to-lower crankcase perimeter bolts (1 through 8).
^ Tighten the upper-to-lower crankcase perimeter bolts (1 through 8) to 30 Nm (22 ft. lbs.).