System Specifications
SURFACE VARIATION - HEAD-TO-BLOCKBlock
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 M (6.0 In ) Area 0.11 mm (0.004 in)
Measuring The Overall Length Of The Block Deck 0.22 mm (0.008 in)
Cylinder Head
Cylinder Head Height/Thickness
Measured From The Cylinder Head Deck To The Valve Rocker Arm Cover Seal Surface 120.2 mm (4.732 in)
Surface Flatness
Block Deck - Measured with a 152.4 mm (6.0 in) Area 0.08 mm (0.003 in)
Block Deck - Measuring The Overall Lengthy Of The Cylinder Head 0.1 mm (0.004 in)
CYLINDER BORE DIAMETER
Cylinder Bore Diameter 96.0-96.018 mm (3.779-3.78 in)
CRANKSHAFT JOURNAL DIAMETER & LIMITS
Crankshaft Main Journal Diameter
Production 64.992-65.008 mm (2.558-2.559 in)
Service 64.992 mm (2.558 in)
Crankshaft Main Journal Out-of-round
Production 0.003 mm (0.000118 in)
Service 0.008 mm (0.0003 in)
Crankshaft Main Journal Taper
Production 0.01 mm (0.0004 in)
Service 0.02 mm (0.00078 in)
Crankshaft End Play 0.04-0.2 mm (0.0015-0.0078 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)
Service 26.22 mm (1.0315 in)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 in)
MAIN BEARING CLEARANCE, STANDARD & LIMIT
Crankshaft Main Bearing
Clearance Production 0.02-0.052 mm (0.0008-0.0021 in)
Clearance Service 0.02-0.065 mm (0.0008-0.0025 in)
MAIN BEARING BORE, LIMIT, & OUT OF ROUND
Crankshaft Main Bearing
Bore Diameter 69.871-69.889 mm (2.75-2.51in)
Bore Out-of-Round 0.006 mm (0.0002 in)
MAIN BEARING CAP TORQUE AND SEQUENCE
Crankshaft Bearing Cap M10 Bolts
First Pass in Sequence 20 Nm (15 lb ft)
Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap M10 Studs
First Pass in Sequence 20 Nm (15 lb ft)
Final Pass in Sequence 51 degrees
M8 Bolts (1-5)
First Pass in Sequence 20 Nm (15 lb ft)
Second Pass In Sequence 30 Nm (22 lb ft)
M8 Bolts (6-10)
First Pass In Sequence 20 Nm (15 lb ft)
Second Pass In Sequence 30 Nm (22 lb ft)
CONNECTING ROD SIDE CLEARANCE, OUT-OF-ROUND & DIAMETER
Connecting Rod Side Clearance 0.11-0.51 mm (0.00433-0.02 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)
Service 0.004-0.008 mm (0.00015-0.0003 in)
Connecting Rod Journal Diameter
Production 53.318-53.338 mm (2.0991-2.0999 in)
Service 53.308 mm (2.0987 in)
Connecting Rod Journal Out-of-Round
Production 0.005 mm (0.0002 in)
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)
Service 0.02 mm (0.00078 in)
CONNECTING ROD BEARING CLEARANCE
Connecting Rod Bearing Clearance
Production 0.023-0.065 mm (0.0009-0.0025 in)
Service 0.023-0.076 mm (0.0009-0.003 in)
PISTON DIMENSIONS AND CLEARANCES
Piston Diameter - Measured Over Skirt Coating 96.002-96.036 mm (3.7796-3.7809 in)
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)
PISTON RING GAP & GROOVE CLEARANCE
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)
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)
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 0.4-0.085 mm (0.00157-0.00335 in)
First Compression Ring - Service 0.4-0.085 mm (0.00157-0.00335 in)
Second Compression Ring -Production 0.4-0.078 mm (0.00157-0.0031 in)
Second Compression Ring - Service 0.4-0.078 mm (0.00157-0.0031 in)
Oil Control Ring - Production 0.012-0.2 mm (0.0005-0.0078 in)
Oil Control Ring - Service 0.012-0.2 mm (0.0005-0.0078 in)
CRANKSHAFT PULLEY TORQUE
Crankshaft Balancer Bolt
Step 1 150 Nm (110 lb ft)
Step 2 Loosen 360 degrees
Step 3 125 degrees
Final Step - With Flanged Head 125 degrees