Cylinder Block Assembly: Specifications
Connecting Rod BoltsFirst Pass 20 Nm (15 ft. lbs.)
Final Pass 85 degrees
Crankshaft Balancer Bolt
Installation Pass - to Ensure the Balancer is Completely Installed 330 Nm (240 ft. lbs.)
First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes 50 Nm (37 ft. lbs.)
Final Pass 140 degrees
Crankshaft Bearing Cap
M10 Bolts - First Pass in Sequence 20 Nm (15 ft. lbs.)
M10 Bolts - Final Pass in Sequence 80 degrees
M10 Studs - First Pass in Sequence 20 Nm (15 ft. lbs.)
M10 Studs - Final Pass in Sequence 51 degrees
M8 Bolts 25 Nm (18 ft. lbs.)
Bore 96.0-96.018 mm (3.779-3.78 inch)
^ Stroke 92.0 mm (3.622 inch)
Block
Camshaft Bearing Bore 1 and 5 Diameter 59.62-59.67 mm (2.347-2.349 inch)
Camshaft Bearing Bore 2 and 4 Diameter 59.12-59.17 mm (2.327-2.329 inch)
Camshaft Bearing Bore 3 Diameter 58.62-58.67 mm (2.307-2.309 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)
Cylinder Bore Diameter 96.0-96.018 mm (3.779-3.78 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 (06.0 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)
Connecting Rod
Connecting Rod Bearing Clearance
Production 0.023-0.065 mm (0.0009-0.0025 inch)
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)
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)
Crankshaft
Connecting Rod Journal Diameter
Production 53.318-53.338 mm (2.0991-2.0999 inch)
Service 53.308 mm (2.0987 inch)
Connecting Rod Journal Out-of-Round
Production 0.005 mm (0.0002 inch)
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)
Service 0.02 mm (0.00078 inch)
Crankshaft End Play (0.04-0.2 mm (0.0015-0.0078 inch)
Crankshaft Main Bearing Clearance
Production 0.02-0.052 mm (0.0008-0.0021 inch)
Service 0.02-0.065 mm (0.0008-0.0025 inch)
Crankshaft Main Journal Diameter
Production 64.992-65.008 mm (2.558-2.559 inch)
Service 64.992 mm (2.558 inch)
Crankshaft Main Journal Out-of-Round
Production 0.003 mm (0.000118 inch)
Service 0.008 mm (0.0003 inch)
Crankshaft Main Journal Taper
Production 0.01 mm (0.0004 inch)
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 (00.04 inch) Below Tooth Diameter (0.7 mm (0.028 inch)
Crankshaft Thrust Surface
Production 26.14-26.22 mm (1.029-1.0315 inch)
Service 26.22 mm (1.0315 inch)
Crankshaft Thrust Surface Runout (0.025 mm (0.001 inch)
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore
Production 0.23 0.44 mm (0.009 0.017 in)
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)
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)
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)
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)
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)
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)
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)
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)
Service Limit with Skirt Coating Worn Off 0.071 mm (0.0028 in)