Cylinder Block Assembly: Specifications
Surface Flatness - Block Deck - Measured Within a 152.4 mm (6.0 In) 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)
Surface Flatness - Measured at Gasket Sealing Surfaces and Measured Within a 200 mm (7.87 inch) Area that Includes Two Runner Port Openings; 0.3 mm (0.118 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 Bore Diameter 96.0-96.018 mm (3.779-3 78 inch)
Cylinder Bore Taper - Thrust Side 0.018 mm (0.0007 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 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 Rear Flange Runout 0.05 mm (0.002 inch)
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below Tooth Diameter; 0.7 mm (0.028 inch)
Crankshaft Thrust Surface - Service 26.22 mm (1.0315 inch)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 inch)
Crankshaft End Play 0.04-0.2 mm (0.0015-0.0078 inch)
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.)
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)
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 - Production; 005 mm (0.0002 inch)
Connecting Rod Journal Taper- Maximum for 1/2 of Journal Length - Service 0.02 mm (0.00078 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 to 0 016 mm (0.0014 to 0.0006 inch)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 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 - Oil Control Ring - Measured in Cylinder Bore - Production 0 18-0 75 mm (0.007-0.029 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0 18--0.81 mm (0.007-0.032 inch)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.04-0 085 mm (0.00157-0,0335 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- Production 0 04-0 078 mm (0 00157-0.0031 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Service 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 - Installation Pass - to Ensure the Balancer is Completely Installed 330 Nm (240 ft. lbs.)
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 (32 ft. lbs.)
Crankshaft Balancer Bolt - Final Pass 140 degrees