System Specifications
Connecting Rod BoltsFirst Pass 20 Nm (15 ft. lbs.)
Final Pass 85 degrees
Crankshaft Balancer Bolt
Installation Pass to Ensure the Balancer is Completely Installed 330 Nm (240 ft. lbs.)
First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes 50 Nm (37 ft. lbs.)
Final Pass 140 degrees
Crankshaft Bearing Cap Bolts
Inner Bolts - First Pass in Sequence 20 Nm (15 ft. lbs.)
Inner Bolts - Final Pass in Sequence 80 degrees
Outer Bolt/Studs - First Pass in Sequence 20 Nm (15 ft. lbs.)
Outer Bolt/Studs - Final Pass in Sequence 51 degrees
Crankshaft Bearing Cap Side Bolts 25 Nm (18 ft. lbs.)
Crankshaft Oil Deflector Nuts 25 Nm (18 ft. lbs.)
Crankshaft Position Sensor Bolt 25 Nm (18 ft. lbs.)
Engine Block Coolant Heater 40 Nm (30 ft. lbs.)
Engine Block Oil Gallery/Coolant Plugs 60 Nm (44 ft. lbs.)
^ Bore 101.618 - 101.636 mm (4.0007 - 4.0017 inch)
Block
^ Crankshaft Main Bearing Bore Diameter 69.871 - 69.889 mm (2.75 - 2.751 inch)
^ Crankshaft Main Bearing Bore Out-of-Round 0.006 mm (0.0002 inch)
^ Cylinder Bore Diameter 101.618 - 101.636 mm (4.0007 - 4.0017 inch)
^ Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face 234.57 - 234.82 mm (9.235 - 9.245 inch)
^ Cylinder Head Deck Surface Flatness - Measured within a 152.4 mm (6.0 inch) Area 0.11 mm (0.004 inch)
^ Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck 0.22 mm (0.008 inch)
^ Valve Lifter Bore Diameter 21.417 - 21.443 mm (0.843 - 0.844 inch)
Connecting Rod
^ Connecting Rod Bearing Clearance - Production 0.023 - 0.065 mm (0.0009 - 0.0025 inch)
^ Connecting Rod Bearing Clearance - Service 0.023 - 0.076 mm (0.0009 - 0.003 inch)
^ Connecting Rod Bore Diameter - Bearing End 56.505 - 56.525 mm (2.224 - 2.225 inch)
^ Connecting Rod Bore Out-of-Round - Bearing End - Production 0.004 - 0.008 mm (0.00015 - 0.0003 inch)
^ Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004 - 0.008 mm (0.00015 - 0.0003 inch)
^ Connecting Rod Side Clearance 0.11 - 0.51 mm (0.00433 - 0.02 inch)
Crankshaft
^ Connecting Rod Journal Diameter - Production 53.318 - 53.338 mm (2.0991 - 2.0999 inch)
^ Connecting Rod Journal Diameter - Service 53.308 mm (2.0987 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 - Maximum for 1/2 of Journal Length - Production 0.005 mm (0.0002 inch)
^ Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service 0.02 mm (0.00078 inch)
^ Crankshaft End Play 0.04 - 0.2 mm (0.0015 - 0.0078 inch)
^ Crankshaft Main Bearing Clearance - Production 0.02 - 0.052 mm (0.0008 - 0.0021 inch)
^ Crankshaft Main Bearing Clearance - Service 0.02 - 0.065 mm (0.0008 - 0.0025 inch)
^ Crankshaft Main Journal Diameter - Production 64.992 - 65.008 mm (2.558 - 2.559 inch)
^ Crankshaft Main Journal Diameter - Service 64.992 mm (2.558 inch)
^ Crankshaft Main Journal Out-of-Round - Production 0.003 mm (0.000118 inch)
^ Crankshaft Main Journal Out-of-Round - Service 0.008 mm (0.0003 inch)
^ Crankshaft Main Journal Taper - Production 0.01 mm (0.0004 inch)
^ Crankshaft Main Journal Taper - Service 0.02 mm (0.00078 inch)
^ Crankshaft Rear Flange Runout 0.05 mm (0.002 inch)
^ Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below Tooth Diameter 0.7 mm (0.028 inch)
^ Crankshaft Thrust Surface - Production 26.14 - 26.22 mm (1.029 - 1.0315 inch)
^ Crankshaft Thrust Surface - Service 26.22 mm (1.0315 inch)
^ Crankshaft Thrust Surface Runout 0.025 mm (0.001 inch)
Piston Rings
^ Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.20 - 0.41 mm (0.008 - 0.016 inch)
^ Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.20 - 0.41 mm (0.008 - 0.016 inch)
^ Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.37 - 0.69 mm (0.015 - 0.027 inch)
^ Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.37 - 0.69 mm (0.015 - 0.027 inch)
^ Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.22 - 0.79 mm (0.009 - 0.031 inch)
^ Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.22 - 0.79 mm (0.009 - 0.031 inch)
^ Piston Ring to Groove Clearance - First Compression Ring - Production 0.030 - 0.10 mm (0.0012 - 0.0040 inch)
^ Piston Ring to Groove Clearance - First Compression Ring - Service 0.030 - 0.10 mm (0.0012 - 0.0040 inch)
^ Piston Ring to Groove Clearance - Second Compression Ring - Production 0.035 - 0.078 mm (0.0014 - 0.0031 inch)
^ Piston Ring to Groove Clearance - Second Compression Ring - Service 0.035 - 0.078 mm (0.0014 - 0.0031 inch)
^ Piston Ring to Groove Clearance - Oil Control Ring - Production 0.013 - 0.201 mm (0.0005 - 0.0079 inch)
^ Piston Ring to Groove Clearance - Oil Control Ring - Service 0.013 - 0.201 mm (0.0005 - 0.0079 inch)
Pistons and Pins
^ Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.002 - 0.01 mm (0.0008 - 0.0004 inch)
^ Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.002 - 0.015 mm (0.0008 - 0.0006 inch)
^ Pin - Piston Pin Diameter 23.952 - 23.955 mm (0.943 - 0.943 inch)
^ Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.007 - 0.02 mm (0.00027 - 0.00078 inch)
^ Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.007 - 0.0022 mm (0.00027 - 0.00086 inch)
^ Piston - Piston Diameter - Measured Over Skirt Coating 101.611 - 101.642 mm (4.0 - 4.001 inch)
^ Piston - Piston to Bore Clearance - Production -0.022 - 0.08 mm (-0.0009 - 0.0012 inch)
^ Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.024 - 0.08 mm (0.00094 - 0.0031 inch)