Cylinder Block Assembly: Specifications

Block
Cylinder Bore Diameter - Service Limits 103.11 mm (4.0594 inch)
Cylinder Bore Diameter - Production Value 103.0-103.014 mm (4.0551-4.0557 inch)
Cylinder Bore Out-of-Round - Production Value 0.015 mm (0.0006 inch)
Cylinder Bore Taper - Production Value 0.015 mm (0.0006 inch)
Surface Flatness - Block Deck - Service Limit 0.2 mm (0.0079 inch)
Surface Flatness - Block Deck - Production Value 0.075 mm (0.0030 inch)

Connecting Rod Cap Bolt - Angular Tightening Method
1st Step 64 Nm
1st Step 47 ft. lbs.)
2nd Step 30°
2nd Step 30°
3rd Step 30°
3rd Step 30°

Crankshaft Bearing Cap Bolt
1st Step 98 Nm
1st Step 72 ft. lbs.)
2nd Step 132 Nm
2nd Step 97 ft. lbs.)
3rd Step 30°
3rd Step 30°
Crankshaft Bearing Cap Bolt - Angular Tightening Method
1st Step 100 Nm
1st Step 74 ft. lbs.)
2nd Step 90°
2nd Step 90°
Crankshaft Bearing Cap Side Bolt 70 Nm (52 ft. lbs.)

Crankshaft Balancer Bolt
1st Step 100 Nm
1st Step 74 ft. lbs.)
2nd Step 90°
2nd Step 90°

Connecting Rod
Connecting Rod Bearing Clearance - Service Limit 0.10 mm (0.0039 inch)
Connecting Rod Bearing Clearance - Production Value 0.036-0.077 mm (0.0014-0.0030 inch)
Connecting Rod Bore Diameter - Bearing End - Production Value 62.958-62.979 mm (2.4789-2.4795 inch)
Connecting Rod Bore Diameter - Pin End - Service Limit 34.53 mm (1.3594 inch)
Connecting Rod Bore Diameter - Pin End - Production Value 34.512-34.522 mm (1.3587-1.3591 inch)
Connecting Rod Length 163.0 mm (6.42 inch)
Connecting Rod Side Clearance - Service Limit 0.54 mm (0.0213 inch)
Connecting Rod Side Clearance - Production Value 0.31-0.49 mm (0.0122-0.0193 inch)

Crankshaft
Connecting Rod Journal Diameter - Service Limit 62.88 mm (2.4756 inch)
Connecting Rod Journal Diameter - Production Value 62.902-62.922 mm (2.4764-2.4772 inch)
Crankshaft End Play - Service Limit 0.54 mm (0.0213 inch)
Crankshaft End Play - Production Value 0.04-0.205 mm (0.0016-0.0081 inch)
Crankshaft Main Bearing Clearance - Service Limit 0.14 mm (0.0055 inch)
Crankshaft Main Bearing Clearance - Production Value 0.039-0.070 mm (0.0015-0.0028 inch)
Crankshaft Main Journal Diameter - Service Limit 79.89 mm (3.1453 inch)
Crankshaft Main Journal Diameter - Production Value 79.905-79.925 mm (3.1459-3.1466 inch)
Crankshaft Runout - Service Limit 0.44 mm (0.0173 inch)
Crankshaft Runout - Production Value 0.05 mm (0.0020 inch)

Piston Rings
Piston Ring End Gap-First Compression Ring - Service Limit 1.37 mm (0.0539 inch)
Piston Ring End Gap-First Compression Ring - Production Value 0.3-0.45 mm (0.0118-0.0177 inch)
Piston Ring End Gap-Second Compression Ring - Service Limit 1.35 mm (0.0531 inch)
Piston Ring End Gap-Second Compression Ring - Production Value 0.50-0.65 mm (0.0197-0.0256 inch)
Piston Ring End Gap-Oil Control Ring - Service Limit 1.20 mm (0.0472 inch)
Piston Ring End Gap-Oil Control Ring - Production Value 0.15-0.35 mm (0.0059-0.0138 inch)
Piston Ring to Groove Clearance-First Compression Ring - Service Limit 0.26 mm (0.0102 inch)
Piston Ring to Groove Clearance-First Compression Ring - Production Value 0.08-0.17 mm (0.0030-0.0067 inch)
Piston Ring to Groove Clearance-Second Compression Ring - Service Limit 0.10 mm (0.0039 inch)
Piston Ring to Groove Clearance-Second Compression Ring - Production Value 0.01-0.03 mm (0.0004-0.0012 inch)
Piston Ring to Groove Clearance-Oil Control Ring - Service Limit 0.12 mm (0.0047 inch)
Piston Ring to Groove Clearance-Oil Control Ring - Production Value 0.01-0.03 mm (0.0004-0.0012 inch)

Pistons and Pins
Piston-Piston Diameter 102.948-102.960 mm (4.0531-4.0535 inch)
Piston-Piston Pin Bore Diameter 34.504-34.512 mm (1.3584-1.3587 inch)
Pin-Piston Pin Clearance to Piston Pin Bore - Service Limit 0.017 mm (0.0007 inch)
Pin-Piston Pin Clearance to Piston Pin Bore - Production Value 0.004-0.017 mm (0.0002-0.0007 inch)
Pin-Piston Pin Diameter - Service Limit 34.45 mm (1.3563 inch)
Pin-Piston Pin Diameter - Production Value 34.495-34.5 mm (1.3581-1.3583 inch)