Cylinder Block Assembly: Specifications
Cylinder blockCylinder Head Deck Surface Flatness - Measured within a 152.4 mm (6.0 in) Area 0.11 mm (0.004 in)
Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck 0.22 mm (0.008 in)
Cylinder Bore Diameter 103.241-103.259 mm (4.0065-4.0065 in)
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)
Connecting rod
Connecting Rod Bearing Clearance - Production 0.023-0.065 mm (0.0009-0.0025 in)
Connecting Rod Bearing Clearance - 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)
Connecting Rod Bore Out-of-Round - Bearing End - 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)
Connecting Rod Journal Diameter - Service 53.308 mm (2.0987 in)
Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 in)
Connecting Rod Journal Out-of-Round - 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)
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - 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)
Crankshaft Main Bearing Clearance - 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)
Crankshaft Main Journal Diameter - Service 64.992 mm (2.558 in)
Crankshaft Main Journal Out-of-Round - Production 0.003 mm (90.000118 in)
Crankshaft Main Journal Out-of-Round - Service 0.008 mm (0.0003 in)
Crankshaft Main Journal Taper - Production 0.01 mm (0.0004 in)
Crankshaft Main Journal Taper - 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 in) Below Tooth Diameter 0.7 mm (0.028 in)
Crankshaft Thrust Surface - Production 26.14-26.22 mm (1.029-1.0315 in)
Crankshaft Thrust Surface - Service 26.22 mm (1.0315 in)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 in)
Piston ring
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.23-0.44 mm (0.009-0.017 in)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - 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)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - 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)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - 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)
Piston Ring to Groove Clearance - First Compression Ring - 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)
Piston Ring to Groove Clearance - Second Compression Ring - 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)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.012-0.2 mm (0.0005-0.0078 in)
Pistons
Piston - Piston Diameter - Measured Over Skirt Coating 103.235-103.258 mm (4.064-4.065 in)
Piston - Piston to Bore Clearance - Production -0.036 to +0.016 mm (-0.0014 to +0.0006 in)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.71 mm (0.0028 in)
Main bearing caps
Bolts (1-10) first pass 20 Nm (15 lb ft)
Bolts (1-10) final pass 80 degrees
Studs (11-20) first pass 20 Nm (15 lb ft)
Studs (11-20) final pass 51 degrees
Bolts (1-5) first pass 20 Nm (15 lb ft)
Bolts (1-5) final pass 30 Nm (22 lb ft)
Bolts (6-10) first pass 20 Nm (15 lb ft)
Bolts (6-10) final pass 30 Nm (22 lb ft)
Crankshaft balancer
First pass tighten 150 Nm (110 lb ft)
Second pass loosen 360 degrees
Third pass tighten 50 Nm (37 lb ft)
Final pass tighten 200 degrees