System Specifications
Cylinder blockCylinder bore diameter 94.999-95.001 mm (3.7401-3.7402 in)
Cylinder bore maximum taper 0.076 mm (0.003 in)
Cylinder bore maximum out-of-round 0.05 mm (0.002 in)
Main bearing bore inside diameter 85.99-86.01 mm (3.3854-3.3862 in)
Crankshaft
Main bearing journal diameter- Standard size 80.9873-81.0127 mm (3.188-3.150 in)
Main bearing journal diameter- 0.254 (0.010 in) undersize mm 80.7333-80.7587 mm (3.178-3.140 in)
Main bearing journal diameter- 0.508 mm (0.020 in) undersize 80.4793-80.5047 mm (3.168-3.130 in)
Main bearing journal diameter- 0.762 mm (0.030 in) undersize 80.2253-80.2507 mm (3.158-3.120 in)
Main bearing journal-to-cylinder block clearance 0.020-0.086 mm (0.008-0.0034 in)
Connecting rod journal diameter
Standard size 68.99 to 69.01 mm (2.716 to 2.717 in)
0.254 mm (0.010 in) undersize 68.73 to 68.75 mm (2.706 to 2.707 in)
0.508 mm (0.020 in) undersize 68.48 to 68.50 mm (2.696 to 2.697 in)
0.762 mm (0.030 in) undersize 68.23 to 68.25 mm (2.686 to 2.687 in)
Crankshaft maximum end play 0.508 mm (0.020 in)
Piston and connecting rod
Piston diameter- Standard size 94.9460-94.9186 mm (3.737-3.738 in)
Piston diameter- 0.254 mm (0.010 in) oversize 95.1738-95.1992 mm (3.747-3.748 in)
Piston diameter- 0.508 mm (0.020 in) oversize 95.4278-95.4532 mm (3.757-3.758 in)
Piston diameter - mm (0.030 in) oversize 0.762 95.6818-95.7072 mm (3.767-3.768 in)
Piston-to- cylinder bore clearance 0.0441-0.0909 mm (0.0017-0.0036 in)
Piston ring end gap - top compression 0.29-0.55 mm (0.011-0.021 in)
Piston ring end gap - intermediate compression 1.40-1.66 mm (0.055-0.065 in)
Piston ring end gap- oil control 0.24-0.50 mm (0.009-0.019 in)
Piston ring groove width (measured over 2.08 mm (0.082 in) gauge pins) Upper limit - 94.469 mm (3.7192 in)
Piston ring groove width (measured over 2.08 mm (0.082 in) gauge pins) Replacement limit - 94.290 mm (3.7122 in)
Piston pin diameter 33.9975-34.0025 mm (1.3385-1.3387 in)
Piston pin length 65.073-65.327 mm (2.5619-2.5719 in)
Piston pin-to-piston fit 0.013-0.022 mm (0.0005-0.0009 in)
Connecting rod length (center-to-center) 176 min (6.929 in)
Connecting rod bearing bore diameter 72.987-73.013 mm (2.8735-2.8745 in)
Connecting rod bearing-to-crankshaft clearance 0.0203-0.0837 mm (0.008-0.0033 in)
Connecting rod side clearance 0.3-0.6 mm (0.012-0.024 in)
Surface Variation
Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61 cm (24 inch) long, the machined edge must be flat with 0.010 mm (0.0004 inch) from end to end.
Crankcase Main Bearing bolts
CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in three stages in the sequence shown.
Stage 1: Tighten to 122 Nm (90 ft. lbs.).
Stage 2: Tighten again to 163 Nm (120 ft. lbs.).
Stage 3: Tighten to 231 Nm (170 ft. lbs.).
Install eight M8 x 30 bolts around the outside of the lower crankcase.
Tighten bolts to 31 Nm (23 ft. lbs.) in the sequence shown.
Connecting rod cap
Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
Tighten to 45 Nm (33 ft. lbs.).
Tighten to 68 Nm (50 ft. lbs.).
Crankshaft pulley (6.0L) (dual alternator) 47 Nm (35 ft. lbs.)
CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.
NOTE: Do not use anti-seize compounds, grease, or any lubricants. Lubricants have an adverse effect on the torque results.
Install the crankshaft vibration damper and bolts.
Tighten the bolts in the sequence shown.
Tighten the bolts to 68 Nm (50 ft. lbs.).
Tighten the bolts an additional 90 degrees.