Cylinder Block Assembly: Specifications

Cylinder bore diameter 96.82 mm (3.81 inch)
Cylinder bore diameter surface finish 0.2-0.6 (RMS)
Cylinder bore maximum out-of-round limit 0.025 mm (0.001 inch)
Cylinder bore maximum taper 0.050 mm (0.002 inch)
Cylinder bore maximum out-of-round service limit 0.127 mm (0.005 inch)
Cylinder bore maximum taper service limit 0.254 mm (0.010 inch)
Main bearing bore inside diameter 68.905 mm (2.713 inch) 68.885 mm (2.712 inch)
Camshaft bearing bore inside diameter
Head gasket surface flatness 0.08 mm (0.003 inch) in 152.0 mm (6.00 inch)
Main bearing journal diameter 1, 2, 3 63.978-63.998 mm (2.5188-2.5196 inch)
Main bearing journal maximum taper 0.016 mm D or 0.008 mm R MAX between any two measurement points
Main bearing journal maximum out-of-round 0.0008 mm MAX in 45 degrees, 0.016 mm (0.006 inch) TOTAL
Main bearing journal-to-cylinder block clearance-desired 0.025-0.035 mm (0.001-0.0014 inch)
Main bearing journal-to-cylinder block clearance-allowable 0.013-0.058 mm (0.0005-0.0023 inch)
Connecting rod journal diameter 58.682-58.702 mm (2.3103-2.3111 inch)
Connecting rod journal maximum taper 0.016 mm D or 0.008 mm R MAX between any two measurement points
Connecting rod journal maximum out-of-round 0.008 mm (0.0003 inch) MAX in 45 degrees, 0.015 mm (0.0006 inch) TOTAL Crankshaft maximum end play 0.010-0.20 mm (0.0004-0.008 inch)
Pistons and Connecting Rod
Piston diameter-coded red (before coating) 96.795-96.782 mm (3.81082-3.81031 inch)
Piston diameter-coded blue (before coating) 96.808-96.795 mm (3.81133-3.81082 inch)
Piston diameter-coded yellow (before coating) 96.821-96.808 mm (3.81184-3.81133 inch)
Piston-to-cylinder bore clearance (uncoated clearance) 0.018-0.044 mm (0.0007-0.0017 inch)
Piston ring end gap-compression (top, in gauge) 0.17-0.33 mm (0.0067-0.0130 inch)
Piston ring end gap-compression (bottom, in gauge) 0.3-0.55 mm (0.0118-0.0217 inch)
Piston ring end gap-oil ring (steel rail, in gauge) 0.15-0.65 mm (0.0059-0.0256 inch)
Piston ring groove width-compression (top) 1.535-1.52 mm (0.0604-0.0598 inch)
Piston ring groove width-compression (bottom) 1.54-1.52 mm (0.0606-0.0598 inch)
Piston ring groove width-oil 3.05-3.03 mm (0.1200-0.1193 inch)
Piston ring width-compression (top) 1.47-1.49 mm (0.0578-0.0587 inch)
Piston ring width-compression (bottom) 1.47-1.49 mm (0.0578-0.0587 inch)
Piston ring width-oil ring side seal-snug fit
Piston ring-to-groove clearance-1st ring 0.030-0.065 mm (0.0012-0.0026 inch)
Piston ring-to-groove clearance-2nd ring 0.030-0.070 mm (0.0012-0.0028 inch)
Piston pin bore diameter 23.012-23.012 mm (0.9060-0.9061 inch)
Piston pin diameter 23.000-23.003 mm (0.9055-0.9056 inch)
Piston pin length 63.55-63.05 mm (2.5096-2.4823 inch)
Piston pin-to-piston fit 0.009-0.017 mm (0.0004-0.0007 inch)
Connecting rod-to-pin clearance press fit 8 kilonewtons (1,800 lb)
Connecting rod pin bore diameter 22.98-22.941 mm (0.9047-0.9032 inch)
Connecting rod length (center-to-center) 154.66-154.74 mm (6.08896-6.09211 inch)
Connecting rod maximum allowed bend 0.04 per 25 mm (0.0016 per inch)
Connecting rod maximum allowed twist 0.05 per 25 mm (0.002 per inch)
Connecting rod bearing bore diameter 61.635-61.655 mm (2.4266-2.4274 inch)
Connecting rod bearing-to-crankshaft clearance-desired 0.025-0.035 mm (0.001-0.0014 inch)
Connecting rod bearing-to-crankshaft clearance-allowable 0.022-0.069 mm (0.00086-0.0027 inch)
Connecting rod side clearance-standard 0.11-0.49 mm (0.0047-0.0193 inch)
Connecting rod side clearance-service limit 0.49 mm MAX (0.0193 in MAX)
Crankshaft pulley bolt 160 Nm (118 ft. lbs.)
Connecting Rod Cap Bolts
Stage 1 25 Nm (18 ft. lbs.)
Stage 2 45 Nm (33 ft. lbs.)
Stage 3 Tighten an additional 105 degrees.
Main Bearing Caps Bolts
Stage 1 50 Nm (37 ft. lbs.)
Stage 2 Rotate an additional 120 degrees.