Cylinder Block Assembly: Specifications
Block^ Camshaft Bearing Bore 1 and 5 Diameter 59.62 - 59.67 mm (2.347 - 2.349 in)
^ Camshaft Bearing Bore 2 and 4 Diameter 59.12 - 59.17 mm (2.327 - 2.329 in)
^ Camshaft Bearing Bore 3 Diameter 58.62 - 58.67 mm (2.307 - 2.309 in)
^ Crankshaft Main Bearing Bore Diameter 69.871 - 69.889 mm (2.75 - 2.751 in)
^ Crankshaft Main Bearing Bore Out-of-Round 0.006 mm (0.0002 in)
^ Cylinder Bore Diameter 96.0 - 96.018 mm (3.779 - 3.78 in)
^ Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face 234.57 - 234.82 mm (9.235 - 9.245 in)
^ Cylinder Head Deck Surface Flatness - Measured within a 152.4 mm (6.0 in) Area 0.11 mm (0.004 in)
^ Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck 0.22 mm (0.008 in)
^ Valve Lifter Bore Diameter 21.417 - 21.443 mm (0.843 - 0.844 in)
Camshaft
^ Camshaft End Play 0.025 - 0.305 mm (0.001 - 0.012 in)
^ Camshaft Journal Diameter 54.99 - 55.04 mm (2.164 - 2.166 in)
^ Camshaft Journal Out-of-Round 0.025 mm (0.001 in)
^ Camshaft Lobe Lift - Exhaust 6.96 mm (0.274 in)
^ Camshaft Lobe Lift - Intake 6.82 mm (0.268 in)
^ Camshaft Runout - Measured at the Intermediate Journals 0.05 mm (0.002 in)
Connecting Rod
^ Connecting Rod Bearing Clearance - Production 0.023 - 0.065 mm (0.0009 - 0.0025 in)
^ Connecting Rod Bearing Clearance - Service 0.023 - 0.076 mm (0.0009 - 0.003 in)
^ Connecting Rod Bore Diameter - Bearing End 56.505 - 56.525 mm (2.224 - 2.225 in)
^ Connecting Rod Bore Out-of-Round - Bearing End - Production 0.004 - 0.008 mm (0.00015 - 0.0003 in)
^ Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004 - 0.008 mm (0.00015 - 0.0003 in)
^ Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 in)
Crankshaft
^ Connecting Rod Journal Diameter - Production 53.318 - 53.338 mm (2.0991 - 2.0999 in)
^ Connecting Rod Journal Diameter - Service 53.308 mm (2.0987 in)
^ Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 in)
^ Connecting Rod Journal Out-of-Round - Service 0.01 mm (0.0004 in)
^ Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production 0.005 mm (0.0002 in)
^ Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service 0.02 mm (0.00078 in)
^ Crankshaft End Play 0.04 - 0.2 mm (0.0015 - 0.0078 in)
^ Crankshaft Main Bearing Clearance - Production 0.02 - 0.052 mm (0.0008 - 0.0021 in)
^ Crankshaft Main Bearing Clearance - Service 0.02 - 0.065 mm (0.0008 - 0.0025 in)
^ Crankshaft Main Journal Diameter - Production 64.992 - 65.008 mm (2.558 - 2.559 in)
^ Crankshaft Main Journal Diameter - Service 64.992 mm (2.558 in)
^ Crankshaft Main Journal Out-of-Round - Production 0.003 mm (0.000118 in)
^ Crankshaft Main Journal Out-of-Round - Service 0.008 mm (0.0003 in)
^ Crankshaft Main Journal Taper - Production 0.01 mm (0.0004 in)
^ Crankshaft Main Journal Taper - Service 0.02 mm (0.00078 in)
^ Crankshaft Rear Flange Runout 0.05 mm (0.002 in)
^ Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter 0.7 mm (0.028 in)
^ Crankshaft Thrust Surface - Production 26.14 - 26.22 mm (1.029 - 1.0315 in)
^ Crankshaft Thrust Surface - Service 26.22 mm (1.0315 in)
^ Crankshaft Thrust Surface Runout 0.025 mm (0.001 in)
Block
^ Camshaft Bearing Bore 1 and 5 Diameter 59.62 - 59.67 mm (2.347 - 2.349 in)
^ Camshaft Bearing Bore 2 and 4 Diameter 59.12 - 59.17 mm (2.327 - 2.329 in)
^ Camshaft Bearing Bore 3 Diameter 58.62 - 58.67 mm (2.307 - 2.309 in)
^ Crankshaft Main Bearing Bore Diameter 69.871 - 69.889 mm (2.75 - 2.751 in)
^ Crankshaft Main Bearing Bore Out-of-Round 0.006 mm (0.0002 in)
^ Cylinder Bore Diameter 96.0 - 96.018 mm (3.779 - 3.78 in)
^ Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face 234.57 - 234.82 mm (9.235 - 9.245 in)
^ Cylinder Head Deck Surface Flatness - Measured within a 152.4 mm (6.0 in) Area 0.11 mm (0.004 in)
^ Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck 0.22 mm (0.008 in)
^ Valve Lifter Bore Diameter 21.417 - 21.443 mm (0.843 - 0.844 in)
Camshaft
^ Camshaft End Play 0.025 - 0.305 mm (0.001 - 0.012 in)
^ Camshaft Journal Diameter 54.99 - 55.04 mm (2.164 - 2.166 in)
^ Camshaft Journal Out-of-Round 0.025 mm (0.001 in)
^ Camshaft Lobe Lift - Exhaust 6.96 mm (0.274 in)
^ Camshaft Lobe Lift - Intake 6.82 mm (0.268 in)
^ Camshaft Runout - Measured at the Intermediate Journals 0.05 mm (0.002 in)
Connecting Rod
^ Connecting Rod Bearing Clearance - Production 0.023 - 0.065 mm (0.0009 - 0.0025 in)
^ Connecting Rod Bearing Clearance - Service 0.023 - 0.076 mm (0.0009 - 0.003 in)
^ Connecting Rod Bore Diameter - Bearing End 56.505 - 56.525 mm (2.224 - 2.225 in)
^ Connecting Rod Bore Out-of-Round - Bearing End - Production 0.004 - 0.008 mm (0.00015 - 0.0003 in)
^ Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004 - 0.008 mm (0.00015 - 0.0003 in)
^ Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 in)
Crankshaft
^ Connecting Rod Journal Diameter - Production 53.318 - 53.338 mm (2.0991 - 2.0999 in)
^ Connecting Rod Journal Diameter - Service 53.308 mm (2.0987 in)
^ Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 in)
^ Connecting Rod Journal Out-of-Round - Service 0.01 mm (0.0004 in)
^ Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production 0.005 mm (0.0002 in)
^ Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service 0.02 mm (0.00078 in)
^ Crankshaft End Play 0.04 - 0.2 mm (0.0015 - 0.0078 in)
^ Crankshaft Main Bearing Clearance - Production 0.02 - 0.052 mm (0.0008 - 0.0021 in)
^ Crankshaft Main Bearing Clearance - Service 0.02 - 0.065 mm (0.0008 - 0.0025 in)
^ Crankshaft Main Journal Diameter - Production 64.992 - 65.008 mm (2.558 - 2.559 in)
^ Crankshaft Main Journal Diameter - Service 64.992 mm (2.558 in)
^ Crankshaft Main Journal Out-of-Round - Production 0.003 mm (0.000118 in)
^ Crankshaft Main Journal Out-of-Round - Service 0.008 mm (0.0003 in)
^ Crankshaft Main Journal Taper - Production 0.01 mm (0.0004 in)
^ Crankshaft Main Journal Taper - Service 0.02 mm (0.00078 in)
^ Crankshaft Rear Flange Runout 0.05 mm (0.002 in)
^ Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter 0.7 mm (0.028 in)
^ Crankshaft Thrust Surface - Production 26.14 - 26.22 mm (1.029 - 1.0315 in)
^ Crankshaft Thrust Surface - Service 26.22 mm (1.0315 in)
^ Crankshaft Thrust Surface Runout 0.025 mm (0.001 in)
Piston Rings
^ Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.23 - 0.44 mm (0.009 - 0.017 in)
^ Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.23 - 0.5 mm (0.009 - 0.0196 in)
^ Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.44 - 0.7 mm (0.017 - 0.027 in)
^ Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.44 - 0.76 mm (0.0173 - 0.03 in)
^ Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.18 - 0.75 mm (0.007 - 0.029 in)
^ Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.18 - 0.81 mm (0.007 - 0.032 in)
^ Piston Ring to Groove Clearance - First Compression Ring - Production 0.04 - 0.085 mm (0.00157 - 0.00335 in)
^ Piston Ring to Groove Clearance - First Compression Ring - Service 0.04 - 0.085 mm (0.00157 - 0.00335 in)
^ Piston Ring to Groove Clearance - Second Compression Ring - Production 0.04 - 0.078 mm (0.00157 - 0.0031 in)
^ Piston Ring to Groove Clearance - Second Compression Ring - Service 0.04 - 0.078 mm (0.00157 - 0.0031 in)
^ Piston Ring to Groove Clearance - Oil Control Ring - Production 0.012 - 0.2 mm (0.0005 - 0.0078 in)
^ Piston Ring to Groove Clearance - Oil Control Ring - Service 0.012 - 0.2 mm (0.0005 - 0.0078 in)
Pistons and Pins
^ Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.002 - 0.01 mm (0.00008 - 0.0004 in)
^ Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.002 - 0.015 mm (0.00008 - 0.0006 in)
^ Pin - Piston Pin Diameter 23.952 - 23.955 mm (0.943 - 0.943 in)
^ Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.007 - 0.02 mm (0.00027 - 0.00078 in)
^ Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.007 - 0.022 mm (0.00027 - 0.00086 in)
^ Piston - Piston Diameter - Measured Over Skirt Coating 96.002 - 96.036 mm (3.779 - 3.78 in)
^ Piston - Piston to Bore Clearance - Production -0.036 to 0.016 mm (-0.0014 to 0.0006 in)
^ Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.071 mm (0.0028 in)
Crankshaft Balancer Bolt - Installation Pass - to Ensure the Balancer is Completely Installed 330 Nm (240 ft. lbs.)
Install a NEW Bolt After the Installation Pass
First Pass 50 Nm (37 ft. lbs.)
Final Pass 140 degrees