System 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 104.766-104.784 mm (4.125-4.125 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 Diameter - Pin End 23.511-23.519 mm (0.926-0.926 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 0.19-0.50 mm (0.0075-0.0197 in)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.19-0.56 mm (0.0075-0.0220 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.37-0.69 mm (0.0146-0.0272 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.37-0.75 mm (0.0146-0.0295 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 0.025-0.083 mm (0.0010-0.0033 in)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.025-0.083 mm (0.0010-0.0033 in)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.020-0.060 mm (0.0008-0.0024 in)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.020-0.060 mm (0.0008-0.0024 in)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.023-0.207 mm (0.0009-0.0081 in)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.023-0.207 mm (0.0009-0.0081 in)
Pistons and Pins
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.005-0.013 mm (0.0002-0.0005 in)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.005-0.017 mm (0.0002-0.0007 in)
Pin - Piston Pin Diameter 23.497-23.500 mm (0.9251-0.9252 in)
Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.011-0.022 mm (0.00043-0.00087 in)
Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.011-0.024 mm (0.00043-0.00094 in)
Piston - Piston Diameter - Measured Over Skirt Coating 104.758-104.792 mm (4.1243-4.1257 in)
Piston - Piston to Bore Clearance - Production -0.026 to +0.026 mm (-0.0010 to +0.0010 in)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.081 mm (0.0032 in)
Crankshaft Balancer
First Pass 150 Nm (111 lb ft)
Second Pass Loosen 360 degrees
Third Pass 80 Nm (59 lb ft)
Final Pass 200 degrees
Crankshaft Main Bearing Caps
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)