Cylinder Block Assembly: Specifications
BlockCylinder Bore Diameter 101.618 - 101.643 mm (4.0007 - 4.0017 inch)
Cylinder Bore Out-of-Round - Production 0.017 mm (0.0007 inch)
Cylinder Bore Out-of-Round - Service 0.05 mm (0.002 inch)
Cylinder Bore Taper - Production Relief Side 0.025 mm (0.0010 inch)
Cylinder Bore Taper - Production Thrust Side 0.012 mm (0.0005 inch)
Cylinder Bore Taper - Service 0.025 mm (0.0010 inch)
Cylinder Head Deck Surface Flatness 0.050 - 0.152 mm (0.002 - 0.006 inch)
Piston Rings
Piston Ring End Gap - First Compression Ring - Production 0.25 - 0.40 mm (0.010 - 0.016 inch)
Piston Ring End Gap - Second Compression Ring - Production 0.38 - 0 58 mm (0.015 - 0.023 inch)
Piston Ring End Gap - Oil Control Ring - Production 0.25 - 0.76 mm (0.010 - 0.029 inch)
Piston Ring End Gap - First Compression Ring - Service 0.25 - 0.50 mm (0.010 - 0.020 inch)
Piston Ring End Gap - Second Compression Ring - Service 0.38 - 0.80 mm (0.015 - 0.031 inch)
Piston Ring End Gap - Oil Control Ring - Service 0.005 - 0.090 mm (0.0002 - 0.0035 inch)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.030 - 0.070 mm (0.0012 - 0.0027 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.076 - 0.280 mm (0.0030 - 0.0110 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.046 - 0.196 mm (0.0018 - 0.0077 inch)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.030 - 0.085 mm (0.0012 - 0.0033 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.030 - 0.085 mm (0.0012 - 0.0033 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.076 - 0.200 mm (0.0030 - 0.0079 inch)
Pistons and Pins
Piston - Piston to Bore Clearance - Production 0.018 - 0.061 mm (0.0007 - 0.0024 inch)
Piston - Piston to Bore Clearance - Service 0.075 mm (0.0029 inch)
Pin - Piston Pin Clearance to Connecting Rod Bore - Press Fit 0.012 - 0.048 mm (0.0005 - 0.0019 inch)
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.013 - 0.023 mm (0.0005 - 0.0009 inch)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.025 mm (0.0010 inch)
Pin - Piston Pin Diameter 23.545 - 23.548 mm (0.9270 - 0.9271 inch)
Connecting Rod
Connecting Rod Side Clearance 0.15 - 0.44 mm (0.006 - 0.017 inch)
Connecting Rod Side Clearance 0.15 - 0.44 mm (0.006 - 0.017 inch)
Crankshaft
Connecting Rod Journal Diameter 57.116 - 57.148 mm (2.2487 - 2.2497 inch)
Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
Connecting Rod Journal Out-of-Round - Service 0.025 mm (0.0010 inch)
Connecting Rod Journal Taper - Production 0.00508 mm (0.00030 inch)
Connecting Rod Journal Taper - Service 0.025 mm (0.0010 inch)
Crankshaft
Crankshaft End Play 0.050 - 0.20 mm (0.002 - 0.008 inch)
Crankshaft Main Bearing Clearance #1 - Production 0.02 - 0.05 mm (0.0008 - 0.0020 inch)
Crankshaft Main Bearing Clearance #2, #3, and #4 - Production 0.028 - 0.058 mm (0.0011 - 0.0023 inch)
Crankshaft Main Bearing Clearance #1 - Service 0.0254 - 0.05 mm (0.0010 - 0.0020 inch)
Crankshaft Main Bearing Clearance #2, #3, and #4 - Service 0.025 - 0.063 mm (0.0010 - 0.0025 inch)
Crankshaft Main Journal Diameter #1 62.199 - 62.217 mm (2.4488 - 2.4495 inch)
Crankshaft Main Journal Diameter #2 and #3 62.191 - 62.215 mm (2.4485 - 2.4494 inch)
Crankshaft Main Journal Diameter #4 62.179 - 62.203 mm (2.4480 - 2.4489 inch)
Crankshaft Main Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
Crankshaft Main Journal Out-of-Round - Service 0.025 mm (0.0010 inch)
Crankshaft Main Journal Taper 0.007 mm (0.0003 inch)
Crankshaft Pulley Bolt 58 Nm (43 ft. lbs.)
Crankshaft Balancer Bolt 95 Nm (70 ft. lbs.)
Crankshaft Balancer Remover/Installer Bolt 25 Nm (18 ft. lbs.)
Crankshaft Bearing Cap Bolt - Preferred Method
First Pass 20 Nm (15 ft. lbs.)
Final Pass 73 degrees
Crankshaft Bearing Cap Bolt - Optional Strategy 105 Nm (77 ft. lbs.)
Crankshaft Main Bearing Bore Out-of-Round 0.050 mm (0.002 inch)