System Specifications
ENGINE MECHANICAL SPECIFICATIONSSurface Flatness - Block Deck Measured Within a 152.4 mm (6.0 in) Area 0.08 mm (0.003 in)
Surface Flatness - Block Deck - Measuring the Overall Length of the Cylinder Head 0.1 mm (0.004 in)
Cylinder Bore Diameter 101.618-101.636 mm (4.0007-4.0017 in)
Cylinder Bore Taper - Thrust Side 0.018 mm (0.0007 in)
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
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 64.993-65.007 mm (2.558-2.559 in)
Crankshaft Main Journal Diameter - Service 64.993 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)
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)
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 0.006 mm (0.0002 in)
Connecting Rod Bore Out-of-Round - Bearing End - Service 0.006 mm (0.0002 in)
Connecting Rod Side Clearance 0.11-0.51 mm (0.00433-0.02 in)
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.31-0.52 mm (0.012-0.02 in)
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.31-0.59 mm (0.0122-0.023 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.51-0.77 mm (0.02-0.03 in)
Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.51-0.84 mm (0.02-0.033 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.31-0.87 mm (0.0122-0.034 in)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.31-0.94 mm (0.0122-0.037 in)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.04-0.08 mm (0.00157-0.0031 in)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.04-0.08 mm (0.00157-0.0031 in)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.039-0.079 mm (0.0015-0.0031 in)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.039-0.079 mm (0.0015-0.0031 in)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.015-0.199 mm (0.0006-0.0078 in)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.015-0.199 mm (0.0006-0.0078 in)
Pistons and Pins
Piston - Piston Diameter - Measured Over Skirt Coating 101.606-101.640 mm (4.0002-4.0016 in)
Piston - Piston to Bore Clearance - Production 0.022-0.03 mm - interference (0.0009-0.0012 in - interference)
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.07 mm (0.0028 in)
Pin - Piston Pin Fit in Connecting Rod Bore 0.02-0.043 mm - interference (0.00078-0.00169 in -
interference)
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.011-0.018 mm (0.0004-0.0007 in)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.011-0.02 mm (0.0004-0.0008 in)
Pin - Piston Pin Diameter 23.997-24.0 mm (0.9447-0.9448 in)
FASTENER TIGHTENING SPECIFICATIONS
Crankshaft Balancer Bolt Installation Pass - to Ensure the Balancer is Completely Installed 330 N.m (240 lb ft)
Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes 50 N.m (37 lb ft)
Crankshaft Balancer Bolt - Final Pass 140 degrees
Crankshaft Bearing Cap Bolts - Inner Bolts - First Pass in Sequence 20 N.m (15 lb ft)
Crankshaft Bearing Cap Bolts - Inner Bolts - Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap Bolts - Outer Bolts - First Pass in Sequence 20 N.m (15 lb ft)
Crankshaft Bearing Cap Bolts - Outer Bolts - Final Pass in Sequence 51 degrees
Crankshaft Bearing Cap Side Bolts 25 N.m (18 lb ft)
Crankshaft Oil Deflector Nuts 25 N.m (18 lb ft)
Crankshaft Position Sensor Bolt 25 N.m (18 lb ft)
Connecting Rod Bolts - First Pass 20 N.m (15 lb ft)
Connecting Rod Bolts - Final Pass 75 degrees