Cylinder Block Assembly: Specifications
BlockCrankshaft 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.)
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 Side Clearance 0.11-0.51 mm (0.00433-0.02 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.)
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore -
Production 0.20-0.41 mm (0.0079-0.0161 in.)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore -
Service 0.20-0.46 mm (0.0079-0.0181 in.)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore -
Production 0.37-0.69 mm (0.0146-0.0272 in.)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore -
Service 0.37-0.75 mm (0.0146-0.0295 in.)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore -
Production 0.22-0.79 mm (0.0086-0.0311 in.)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore -
Service 0.22-0.84 mm (0.0086-0.0331 in.)
Piston Ring-to-Groove Clearance - First Compression Ring - P
roduction 0.04-0.083 mm (0.0016-0.0033 in.)
Piston Ring-to-Groove Clearance - First Compression Ring -
Service 0.04-0.083 mm (0.0016-0.0033 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 Pin
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 101.615-101.649 mm (4.0006-4.0019 in.)
Piston - Piston to Bore Clearance - Production -0.031 to +0.021 mm (-0.0012 to +0.0008 in.)
Piston - Piston to Bore Clearance - Service
Limit With Skirt Coating Worn Off 0.071 mm (0.0028 in.)
Harmonic Balancer - Crankshaft Pulley
Tighten the USED bolt to 330 Nm (240 lb ft)
Remove the USED crankshaft balancer bolt.
Tighten the NEW bolt a first pass to 50 Nm (37 lb ft).
Tighten the bolt a final pass to 140 degrees
Main Bearing Cap Bolts
Crankshaft Bearing Cap M8 Bolts 25 Nm (18 lb ft.)
Crankshaft Bearing Cap M10 Bolts - First Pass in Sequence 20 Nm (15 lb ft.)
Crankshaft Bearing Cap M10 Bolts - Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap M10 Studs - First Pass in Sequence 20 Nm (15 lb ft.)
Crankshaft Bearing Cap M10 Studs - Final Pass in Sequence 51 degrees