System Specifications
BlockCamshaft Bearing Bore 1 and 5 Diameter 59.58-59.63 mm (2.345-2.347 in)
Camshaft Bearing Bore 2 and 4 Diameter 59.08-59.13 mm (2.325-2.327 in)
Camshaft Bearing Bore 3 Diameter 58.58-58.63 mm (2.306-2.308 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 101.618-101.636 mm (4.0007-4.0017 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)
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 0.20-0.41 mm (0.008-0.016 in)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.20-0.41 mm (0.008-0.016 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.37-0.69 mm (0.015-0.027 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.37-0.69 mm (0.015-0.027 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.22-0.79 mm (0.009-0.031 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.22-0.79 mm (0.009-0.031 in)
Piston Ring-to-Groove Clearance - First Compression Ring - Production 0.030-0.10 mm (0.0012-0.0040 in)
Piston Ring-to-Groove Clearance - First Compression Ring - Service 0.030-0.10 mm (0.0012-0.0040 in)
Piston Ring-to-Groove Clearance - Second Compression Ring - Production 0.035-0.078 mm (0.0014-0.0031 in)
Piston Ring-to-Groove Clearance - Second Compression Ring - Service 0.035-0.078 mm (0.0014-0.0031 in)
Piston Ring-to-Groove Clearance - Oil Control Ring - Production 0.013-0.201 mm (0.0005-0.0079 in)
Piston Ring-to-Groove Clearance - Oil Control Ring - Service 0.013-0.201 mm (0.0005-0.0079 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 (0.9429-0.9431 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 0.007-0.0022 mm (0.00027-0.000086 in)
Piston - Piston Diameter - Measured Over Skirt Coating 101.611-101.642 mm (4.0-4.001 in)
Piston - Piston to Bore Clearance - Production -0.022 to +0.08 mm (-0.0009 to +0.0012 in)
Piston - Piston to Bore Clearance - Service Limit With Skirt Coating Worn Off 0.024-0.08 mm (0.00094-0.0031 in)
Connecting Rod Bolts - First Pass 20 N.m (15 lb ft)
Connecting Rod Bolts - Final Pass 85 degrees
Crankshaft Balancer Bolt - Installation Pass - to Ensure the Balancer is Completely Installed 330 N.m (240 lb ft)
Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes 50 N.m (37 lb ft)
Crankshaft Balancer Bolt - Final Pass 140 degrees
Crankshaft Bearing Cap M8 Bolts 25 N.m (18 lb ft)
Crankshaft Bearing Cap M10 Bolts - First Pass in Sequence 20 N.m (15 lb ft)
Crankshaft Bearing Cap M10 Bolts - Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap M10 Studs - First Pass in Sequence 20 N.m (15 lb ft)
Crankshaft Bearing Cap M10 Studs - Final Pass in Sequence 51 degrees