Cylinder Block Assembly: Specifications

Block
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 96.0-96.018 mm (3.779-3.78 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 0.23-0.44 mm (0.009-0.017 in.)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore -
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.)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore -
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.)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore -
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.)
Piston Ring-to-Groove Clearance - First Compression Ring -
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.)
Piston Ring-to-Groove Clearance - Second Compression Ring -
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.)
Piston Ring-to-Groove Clearance - Oil Control Ring -
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.)
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 (0.9430-0.9431 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 0.007-0.022 mm (0.00027-0.00086 in.)
Piston - Piston Diameter - Measured Over Skirt
Coating 96.002-96.036 mm (3.7796-3.7809 in.)
Piston - Piston to Bore Clearance -
Production -0.036 to +0.016 mm (-0.0014 to +0.0006 in.)
Piston - Piston to Bore Clearance - Service Limit with Skirt
Coating Worn Off 0.071 mm (0.0028 in.)

NEW Crankshaft Bearing Cap Bolts








M8 Bolts (1-5) - First Pass in Sequence 20 Nm (15 lb ft.)
M8 Bolts (1-5) - Second Pass in Sequence 30 Nm (22 lb ft.)
M8 Bolts (6-10) - First Pass in Sequence 20 Nm (15 lb ft.)
M8 Bolts (6-10) - Second Pass in Sequence 30 Nm (22 lb ft.)
M10 Bolts - First Pass in Sequence 20 Nm (15 lb ft.)
M10 Bolts - Final Pass in Sequence 80 degrees
M10 Studs - First Pass in Sequence 20 Nm (15 lb ft.)
M10 Studs - Final Pass in Sequence 51 degrees

Crankshaft Balancer Bolt
Step 1 150 Nm (110 lb ft.)
Step 2 Loosen 360 degrees
Step 3 80 Nm (59 lb ft.)
Final Step 125 degrees