Cylinder Block Assembly: Specifications

Block
* Crankshaft Main Bearing Bore Diameter 77.0-77.024 mm (3.031-3.032 inch)
* Cylinder Bore Diameter - Production 89.0-89.015 mm (3.5039-3.5045 inch)
* Cylinder Bore Diameter - Service 89.065 mm (3.5065 inch)
* Cylinder Bore Diameter - 0.25 mm (0.0098 inch) Oversize Piston 89.25-89.265 mm (3.5138-3.5144 inch)
* Cylinder Bore Taper - Service 0.05 mm (0.002 inch)
* Cylinder Head Deck Surface Flatness - Production 0.07 mm (0.003 inch)
* Cylinder Head Deck Surface Flatness - Service 0.1 mm (0.004 inch)
* Cylinder Reboring Limit - Service 0.25 mm (0.01 inch)
* Rear Housing-to-Oil Seal Clearance 0.5-0.8 mm (0.019-0.031 inch)

Connecting Rod
* Bearing Clearance - Production 0.02-0.044 mm (0.0008-0.0017 inch)
* Bearing Clearance - Service 0.05 mm (0.002 inch)
* Bore Diameter - Bearing End 58 mm (2.28 inch)
* Bore Diameter - Pin End 21.97-21.976 mm (0.865-0.8652 inch)
* Bore Out-of-Round - Bearing End 0.005 mm (0.0002 inch)
* Length 158.5 mm (6.24 inch)
* End Play - Production 0.15-0.35 mm (0.006-0.014 inch)
* End Play - Service 0.45 mm (0.018 inch)
* Connecting Rod Bolt - Difference in Diameter - Service 0.0-0.1 mm (0.0-0.004 inch)

Crankshaft
* Connecting Rod Journal Diameter 54.976-55.0 mm (2.1644-2.1654 inch)
* Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
* Connecting Rod Journal Out-of-Round - Service 0.01 mm (0.0004 inch)
* Connecting Rod Journal Taper - Production 0.005 mm (0.0002 inch)
* Connecting Rod Journal Taper - Service 0.01 mm (0.0004 inch)
* Connecting Rod Journal Width 17.55-17.75 mm (0.691-0.699 inch)
* End Play - Production 0.1-0.35 mm )0.004-0.014 inch)
* End Play - Service 0.45 mm (0.018 inch)
* Main Bearing Clearance - Production 0.02-0.044 mm (0.0008-0.0017 inch)
* Main Bearing Clearance - Service 0.05 mm (0.002 inch)
* Main Journal Diameter 71.976-72.0 mm (2.8337-2.8346 inch)
* Main Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
* Main Journal Out-of-Round - Service 0.01 mm (0.0004 inch)
* Main Journal Taper - Production 0.005 mm (0.0002 inch)
* Main Journal Taper - Service 0.01 mm (0.0004 inch)
* Runout - Production - Journals 1 and 4 0.02 mm (0.0008 inch)
* Runout - Production - Journals 2 and 3 0.025 mm (0.001 inch)
* Runout - Service 0.03 mm (0.0012 inch)
* Thrust Surface Distance 0.1-0.35 mm (0.004-0.014 inch)
* Thrust Surface Runout 0.45 mm (0.018 inch)* Main Bearing Clearance - Production 0.02-0.044 mm (0.0008-0.0017 inch)
* Main Bearing Clearance - Service 0.05 mm (0.002 inch)
* Main Journal Diameter 71.976-72.0 mm (2.8337-2.8346 inch)
* Main Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
* Main Journal Out-of-Round - Service 0.01 mm (0.0004 inch)
* Main Journal Taper - Production 0.005 mm (0.0002 inch)
* Main Journal Taper - Service 0.01 mm (0.0004 inch)
* Runout - Production - Journals 1 and 4 0.02 mm (0.0008 inch)
* Runout - Production - Journals 2 and 3 0.025 mm (0.001 inch)
* Runout - Service 0.03 mm (0.0012 inch)
* Thrust Surface Distance 0.1-0.35 mm (0.004-0.014 inch)
* Thrust Surface Runout 0.45 mm (0.018 inch)

Piston Rings
* End Gap - Top - Production 0.2-0.35 mm (0.008-0.014 inch)
* End Gap - Top - Service 0.6 mm (0.024 inch)
* End Gap - Second - Production 0.4-0.55 mm (0.0016-0.022 inch)
* End Gap - Second - Service 0.7 mm (0.028 inch)
* End Gap - Oil - Production 0.2-0.7 mm (0.008-0.028 inch)
* End Gap - Oil - Service 0.8 mm (0.031 inch)
* First Compression Ring - Production 0.02-0.35 mm (0.008-0.014 inch)
* First Compression Ring - Service 0.6 mm (0.024 inch)
* Second Compression Ring - Production 0.4-0.055 mm (0.0016-0.0022 inch)
* Second Compression Ring - Service 0.7 mm (0.028 inch)
* Oil Control Ring - Production 0.2-0.7 mm (0.008-0.028 inch)
* Oil Control Ring - Service 0.8 mm (0.031 inch)
* Piston Ring-to-Groove Clearance - Top - Production 0.055-0.08 mm (0.0022-0.0031 inch)
* Piston Ring-to-Groove Clearance - Top - Service 0.15 mm (0.006 inch)
* Piston Ring-to-Groove Clearance - Second - Production 0.03-0.055 mm (0.0012-0.0022 inch)
* Piston Ring-to-Groove Clearance - Second - Service 0.13 mm (0.005 inch)
* First Compression Ring - Production 0.055-0.08 mm (0.0022-0.0031 inch)
* First Compression Ring - Service 0.13 mm (0.005 inch)
* Second Compression Ring - Production 0.03-0.055 mm (0.0012-0.0022 inch)
* Second Compression Ring - Service 0.13 mm (0.005 inch)
* First Compression Ring Height 1.2 mm (0.05 inch)
* First Compression Width 3.1 mm (0.12 inch)
* Second Compression Height 1.2 mm (0.05 inch)
* Second Compression Width 3.4 mm (0.13 inch)

Pistons
* Diameter - Production - Measure 16 mm (0.63 inch) from Bottom of Skirt 88.975-88.985 mm (3.5029-3.5033 inch)
* Diameter - Service 88.965 mm (3.5026 inch)
* Diameter - 0.25 mm Oversize Piston 89.225-89.235 mm (3.5128-3.5132 inch)
* Out-of-Round - Measured by Clearance to Cylinder Bore 0.08 mm (3.15 inch)
* Pin Bore Diameter 21.96-22.03 mm (0.864-0.867 inch)
* Ring Groove Width - Top - Production 1.24-1.25 mm (0.0488-0.0492 inch)
* Ring Groove Width - Top - Service 1.27 mm (0.05 inch)
* Ring Groove Width - Second - Production 1.22-1.23 mm (0.048-0.0484 inch)
* Ring Groove Width - Second - Service 1.25 mm (0.049 inch)
* Ring Groove Width - Oil - Production 2.805-2.825 mm (0.1104-0.1112 inch)
* Ring Groove Width - Oil - Service 2.85 mm (0.112 inch)
* Piston to Bore Clearance - Production 0.015-0.04 mm (0.0006-0.0016 inch)
* Piston to Bore Clearance - Service 0.08 mm (0.003 inch)

Piston Pin
* Clearance to Connecting Rod Bore - Production 0.005-0.014 mm (0.0002-0.0006 inch)
* Clearance to Connecting Rod Bore - Service 0.019 mm (0.0007 inch)
* Clearance to Piston Pin Bore - Production -0.005 to +0.001 mm (-0.0002 to +0.00004 inch)
* Clearance to Piston Pin Bore - Service 0.004 mm (0.0002 inch)
* Diameter - Production 21.962-21.965 mm (0.8646-0.8648 inch)
* Diameter - Service 21.954 mm (0.8643 inch)
* Length 53.77-54.23 mm )2.116-2.135 inch)

Crankshaft Balancer Bolt - First Pass 64 Nm (47 ft. lbs.)
Crankshaft Balancer Bolt - Final Pass 60 degrees