Cylinder Block Assembly: Specifications
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)
Crankshaft End Play 0.04 - 0.2 mm (0.0015 - 0.0078 inch)
Crankshaft Main Journal Diameter - Production 64.992 - 65.008 mm (2.558 - 2.559 inch)
Crankshaft Main Journal Diameter - Service 64.992 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 Rear Flange Runout 0.05 mm (0.002 inch)
Crankshaft Main Bearing Clearance - Service 0.02 - 0.065 mm (0.0008 - 0.0025 inch)
Crankshaft Main Bearing Clearance - Production 0.02 - 0.052 mm (0.0008 - 0.0021 inch)
Tighten the bearing cap bolts and studs.
Tighten the inner M10 bearing cap bolts first pass in sequence 20 Nm (15 ft. lbs.)
Using a plastic faced hammer, tap the crankshaft rearward then forward to align the thrust bearings.
Tighten the inner M10 bolts final pass in sequence 80 degrees using the J45059.
Tighten the outer M10 bolts/studs first pass in sequence 20 Nm (15 ft. lbs.)
Tighten the outer M10 bolts/studs final pass in sequence 51 degrees using the J45059.
Tighten the bearing cap side M8 bolts to 25 Nm (18 ft. lbs.) Tighten the bolt on one side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap.
Connecting Rod Bolts - First Pass 20 Nm (15 ft. lbs.)
Connecting Rod Bolts - Final Pass 85 degrees
Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 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 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)
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.002 - 0.01 mm (0.00008 - 0.0004 inch)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.002 - 0.015 mm (0.00008 - 0.0006 inch)
Pin - Piston Pin Diameter 23.952 - 23.955 mm (0.943 - 0.943 inch)
Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.007 - 0.02 mm (0.00027 - 0.00078 inch)
Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.007 - 0.022 mm (0.00027 - 0.00086 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)
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 - 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 - 0.00335 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 - 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)
Tighten the USED crankshaft balancer bolt 330 Nm (240 ft. lbs.)
Remove the used crankshaft balancer bolt.
Important: The nose of the crankshaft should be recessed 2.4 - 4.48 mm (0.094 - 0.176 inch) into the balancer bore.
Install a NEW crankshaft balancer bolt.
Tighten the bolt a first pass 50 Nm (37 ft. lbs.)
Tighten the bolt a second pass 140 degrees using J45059.