Cylinder Block Assembly: Specifications

Surface Flatness - Block Deck - Measured Within a 152.4 mm (6.0 inch) Area; 0.08 mm (0.003 inch)
Surface Flatness - Block Deck - Measuring the Overall Length of the Cylinder Head; 0.1 mm (0.004 inch)
Surface Flatness - Exhaust Manifold Deck 0.13 mm (0.005 inch)
Surface Flatness - Intake Manifold Deck 0.08 mm (0.0031 inch)
Valve Guide Installed Height - Measured from the Spring Seat Surface to the Top of the Guide; 17.32 mm (0.682 inch)
Cylinder Bore Diameter 96.0 - 96.018 mm (3.779 - 3.78 inch)
Cylinder Bore Taper - Thrust Side 0.018 mm (0.0007 inch)
Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face; 234.57 - 234.82 mm (9.235 - 9.245 inch)
Cylinder Head Deck Surface Flatness - Measured Within a 152.4 mm (6.0 inch) Area; 0.11 mm (0.004 inch)
Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck; 0.22 mm (0.008 inch)
Cylinder Head Height/Thickness - Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface; 120.2 mm (4.732 inch)
Crankshaft Main Bearing Clearance - Production 0.02 - 0.052 mm (0.0008 - 0.0021 inch)
Crankshaft Main Bearing Clearance - Service 0.02 - 0.065 mm (0.0008 - 0.0025 inch)
Crankshaft Main Journal Diameter - Production 64.993 - 65.007 mm (2.558 - 2.559 inch)
Crankshaft Main Journal Diameter - Service 64.993 mm (2.558 inch)
Crankshaft Main Journal Out-of-Round - Production 0.003 mm (0.000118 inch)
Crankshaft Main Journal Out-of-Round - Service 0.008 mm (0.0003 inch)
Crankshaft Main Journal Taper - Production 0.01 mm (0.0004 inch)
Crankshaft Main Journal Taper - Service 0.02 mm (0.00078 inch)
Crankshaft Main Bearing Bore Diameter 69.871 - 69.889 mm (2.75 - 2.751 inch)
Crankshaft Main Bearing Bore Out-of-Round 0.006 mm (0.0002 inch)

Crankshaft Main Bearing Bolt Torque Sequence:

Crankshaft Bearing Cap Bolts - Inner Bolts - First Pass in Sequence 20 Nm (15 ft. lbs.)
Crankshaft Bearing Cap Bolts - Inner Bolts - Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap Bolts - Outer Bolts - First Pass in Sequence 20 Nm (15 ft. lbs.)
Crankshaft Bearing Cap Bolts - Outer Bolts - Final Pass in Sequence 51 degrees
Crankshaft Bearing Cap Side Bolts 25 Nm (18 ft. lbs.)
Crankshaft End Play 0.04 - 0.2 mm (0.0015 - 0.0078 inch)
Crankshaft Rear Flange Runout 0.05 mm (0.002 inch)
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below 0.7 mm (0.028 inch)
Crankshaft Thrust Surface - Production 26.14 - 26.22 mm (1.029 - 1.0315 inch)
Crankshaft Thrust Surface - Service 26.22 mm (1.0315 inch)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 inch)
Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 inch)
Connecting Rod Journal Diameter - Production 53.318 - 53.338 mm (2.0991 - 2.0999 inch)
Connecting Rod Journal Diameter - Service 53.308 mm (2.0987 inch)
Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
Connecting Rod Journal Out-of-Round - Service 0.01 mm (0.0004 inch)
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length 0.005 mm (0.0002 inch)
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length 0.02 mm (0.00078 inch)
Connecting Rod Bearing Clearance - Production 0.023 - 0.065 mm (0.0009 - 0.0025 inch)
Connecting Rod Bearing Clearance - Service 0.023 - 0.076 mm (0.0009 - 0.003 inch)
Connecting Rod Bore Diameter - Bearing End 56.505 - 56.525 mm (2.224 - 2.225 inch)
Connecting Rod Bore Out-of-Round - Bearing End - Production 0.004 - 0.008 mm (0.00015 - 0.0003 inch)
Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004 - 0.008 mm (0.00015 - 0.0003 inch)
Piston - Piston Diameter - Measured Over Skirt Coating 96.002 - 96.036 mm (3.779 - 3.78 inch)
Piston - Piston to Bore Clearance - Production 0.036 - 0.016 mm (0.0014 - 0.0006 inch)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating 0.071 mm (0.0028 inch)
Pin - Piston Pin Fit In Connecting Rod Bore 0.02 - 0.043 mm Interference (0.00078 - 0.00169 inch) Interference
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.007 - 0.02 mm (0.00027 - 0.00078 inch)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.007 - 0.021 mm (0.00027 - 0.00082 inch)
Pin - Piston Pin Diameter 23.997 - 24.0 mm (0.9447 - 0.9448 inch)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.23 - 0.44 mm (0.009 - 0.017 inch)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.23 - 0.5 mm (0.009 - 0.0196 inch)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.44 - 0.7 mm (0.017 - 0.027 inch)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service (0.44 - 0.76 mm (0.0173 - 0.03 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore 0.18 - 0.75 mm (0.007 - 0.029 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore 0.18 - 0.81 mm (0.007 - 0.032 inch)
Piston Ring to Groove Clearance - First Compression Ring 0.04 - 0.085 mm (0.00157 - 0.00335 inch)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.04 - 0.085 mm (0.00157 - 0.00335 inch)
Piston Ring to Groove Clearance - Second Compression Ring 0.04 - 0.078 mm (0.00157 - 0.0031 inch)
Piston Ring to Groove Clearance - Second Compression Ring 0.04 - 0.078 mm (0.00157 - 0.0031 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.012 - 0.2 mm (0.0005 - 0.0078 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.012 - 0.2 mm (0.0005 - 0.0078 inch)
Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes; 50 Nm (37 ft. lbs.)
Crankshaft Balancer Bolt - Final Pass 140 degrees