System Specifications
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 101.618 - 101.636 mm (4.0007 - 4.0017 inch)
Cylinder Bore Taper - Thrust Side 0.018 mm (0.0007 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 Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below Tooth Diameter 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)
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 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)
Main Bearing Cap
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 0.006 mm (0.00023 inch)
Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004 - 0.008 mm (0.00015 - 0.0003 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 0.005 mm (0.0002 inch)
Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service 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)
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 Coating - at Size Point 101.611 - 101.642 mm (4.0 - 4.001 inch)
Piston - Piston to Bore Clearance - Production -0.022 to 0.030 mm (-0.0009 to 0.0012 inch)
Piston - Piston to Bore Clearance - With Skirt Coating Worn Off - Service 0.024 - 0.08 mm (0.00094 - 0.0031 inch)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.31 - 0.52 mm (0.012 - 0.02 inch)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.31 - 0.59 mm (0.0122 - 0.023 inch)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.51 - 0.77 mm (0.02 - 0.03 inch)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.51 - 0.84 mm (0.02 - 0.033 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.31 - 0.87 mm (0.0122 - 0.034 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.31 - 0.94 mm (0.0122 - 0.037 inch)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.035 - 0.08 mm (0.0014 - 0.0031 inch)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.035 - 0.08 mm (0.0014 - 0.0031 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.034 - 0.079 mm (0.0013 - 0.003 inch)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.034 - 0.079 mm (0.0013 - 0.003 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.012 - 0.2 mm (0.00047 - 0.00078 inch)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.012 - 0.2 mm (0.00047 - 0.00078 inch)
Crankshaft Pulley
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.