System Specifications
SURFACE VARIATION - HEAD-TO-BLOCKCylinder head must be flat within:
Standard dimension = less than 0.05 mm (0.002 inch.)
Service Limit = 0.2 mm (0.008 inch.)
Grinding Limit = Maximum of 0.2 mm (0.008 inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.
CYLINDER BORE
Bore Diameter 96.0 mm ± 0.0076 (3.780 in. ± 0.0003 in.)
Out of Round (MAX) 0.006 mm (0.00023 in.)
Taper (MAX) 0.051 mm (0.002 in.)
CRANKSHAFT
Main Journal Diameter 68.987-69.013 mm (2.727-2.716 in.)
Main Bearing Diametrical Clearance 0.032-0.062 mm (0.0013-0.0024 in.)
Bearing Clearance(Wear Limit) 0.070 mm (0.0027 in.)
DIA Out-Of-Round (MAX) 0.007 mm (0.0003 in.)
Diametrical Taper (MAX) 0.006 mm (0.00025 in.)
End Play 0.048-0.260 mm (0.002-0.010 in.)
End Play (MAX) 0.330 mm (0.013 in.)
MAIN BEARING CAP Torque
NOTE: The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts.
NOTE: Lubricate main bearing cap inner bolts (2) with engine oil before installation.
Install each main cap (1) and tighten inner bolts (2) finger tight. Align the location reference mark scribed on the #2 main bearing cap during disassembly.
CAUTION: The #2 main bearing cap must be centered over the inner bolt holes located on the block. Failure to center the bearing cap can result in contact with the crankshaft counterweights and thrust bearing failure.
Following verification of proper #2 bearing cap centering, finish tightening the main bearing cap inner bolts an additional 90° turn.
Install windage tray (3). Lubricate bolts with engine oil. Finger tighten all bolts first, then tighten to 28 Nm + 90° turn (20 ft. lbs. + 90° turn) beginning with the inside bolts tightening outward.
Install oil pickup tube (1) and tighten bolt to 28 Nm (20 ft. lbs.).
Install the main cap tie (horizontal) bolts and tighten to 28 Nm (20 ft. lbs.).
Crankshaft Main Bearing Cap
Inner Main Cap Bolts 20+(1/4) Turn Nm (15+(1/4) Turn ft.lbs)
Outer Main Cap Bolts 27+(1/4) Turn Nm (20+(1/4) Turn ft.lbs)
Tie Bolts (Horizontal) 28 Nm (250 in.lbs)
Main Journal Diameter 68.987-69.013 mm (2.727-2.716 in.)
Main Bearing Diametrical Clearance 0.032-0.062 mm (0.0013-0.0024 in.)
Bearing Clearance(Wear Limit) 0.070 mm (0.0027 in.)
DIA Out-Of-Round (MAX) 0.007 mm (0.0003 in.)
Diametrical Taper (MAX) 0.006 mm (0.00025 in.)
End Play 0.048-0.260 mm (0.002-0.010 in.)
End Play (MAX) 0.330 mm (0.013 in.)
Main Bearing Selection Chart
CONNECTING ROD
Connecting Rod Cap Bolts 27 + 1/4 Turn Nm (20 + 1/4 Turn ft. lbs.)
Side Clearance (MAX) 0.39 mm (0.0153 in.)
Total Weight(Less Bearing) 693 grams (24.445 oz.)
Connecting Rod Bore Diameter 60.994 - 61.006 mm (2.4013 - 2.4018 in.).
Rod Journal Diameter 57.982 - 58.002 mm (2.2828 - 2.2835 in.)
PISTON DIMENSIONS AND CLEARANCES
Piston Diameter 95.98 mm ± 0.019 mm (3.7788 in. ± 0.0008 in.)
Clearance at size Location -0.007 to +0.047 mm (-0.003 to +0.0018 in.)
Piston Weight A 374.4-379.4 grams (13.21-13.38 oz.)
Piston Weight B 379.5-384.4 grams (13.38-13.56 oz.)
Ring Groove Diameter #1 87.4 - 87.6 mm (3.441 - 3.449 in.).
Ring Groove Diameter #2 86.3 - 86.5 mm (3.397 - 3.4055 in.).
Ring Groove Diameter #3 86.5 - 86.7 mm (3.406 - 3.413 in.).
Clearance in Piston 0.005 - 0.015 mm (0.002 - 0.0006 in.).
PISTON RING GAP & GROOVE CLEARANCE
Ring Gap-Top Compression Ring 0.20-0.36 mm (0.008-0.014 in.)
Ring Gap-2nd Compression Ring (Micro-Napier) 0.20-0.40 mm (0.0078-0.0157 in.)
Ring Gap-Oil Control (Steel Rails) 0.25-0.76 mm (0.010-0.030 in.)
CRANKSHAFT PULLEY TORQUE
Crankshaft Damper Bolt 95 Nm (70 ft.lbs.)