Cylinder Block Assembly: Specifications
Cylinder BlockCamshaft Bearing Bore 1 and 5 Diameter 59.58-59.63 mm (2.345-2.347 in)
Camshaft Bearing Bore 2 and 4 Diameter 59.08-59.13 mm (2.325-2.327 in)
Camshaft Bearing Bore 3 Diameter 58.58-58.63 mm (2.306-2.308 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)
Cylinder Bore Diameter 103.241-103.259 mm (4.0646-4.0653 in)
Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face 234.57-234.82 mm (9.235-9.245 in)
Cylinder 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)
Valve Lifter Bore Diameter 21.417-21.443 mm (0.843-0.844 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 (0.000118 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 Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.17-0.38 mm (0.0067-0.0150 in)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.17-0.44 mm (0.0067-0.0173 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.32-0.63 mm (0.0126-0.0248 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.32-0.69 mm (0.0126-0.0272 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.22-0.79 mm (0.0086-0.0311 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.22-0.85 mm (0.0086-0.0335 in)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.030-0.083 mm (0.0012-0.0033 in)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.030-0.083 mm (0.0012-0.0033 in)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.040-0.083 mm (0.0016-0.0033 in)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.040-0.083 mm (0.0016-0.0033 in)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.013-0.201 mm (0.0005-0.0079 in)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.013-0.201 mm (0.0005-0.0079 in)
Pistons and Pins
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.002-0.01 mm (0.00008-0.0004 in)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.002-0.015 mm (0.00008-0.0006 in)
Pin - Piston Pin Diameter 23.952-23.955 mm (0.9430-0.9431 in)
Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.007-0.02 mm (0.00027-0.00078 in)
Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.007-0.022 mm (0.00027-0.00086 in)
Piston - Piston Diameter - Measured Over Skirt Coating 103.258-103.289 mm (4.0653-4.0665 in)
Piston - Piston to Bore Clearance - Production -0.048 to +0.001 mm (-0.0019 to +0.000 in)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.055 mm (0.0022 in)
Crankshaft Balancer
First Pass 150 Nm (111 lb ft)
Second Pass Loosen 360 degrees
Third Pass 80 Nm (59 lb ft)
Final Pass - Without Z52 125 degrees
Final Pass - With Z52 Dry Sump Option 200 degrees
Crankshaft Main Bearing Cap
M10 bolts (1-10) first pass 20 Nm (15 lb ft)
M10 bolts (1-10) final pass 80 degrees
M10 studs (11-20) first pass 20 Nm (15 lb ft)
M10 studs (11-20) final pass 51 degrees
M8 bolts (1-5) first pass 20 Nm (15 lb ft)
M8 bolts (1-5) final pass 30 Nm (22 lb ft)
M8 bolts (6-10) first pass 20 Nm (15 lb ft)
M8 bolts (6-10) final pass 30 Nm (22 lb ft)