System Specifications

Bore 101.618-101.636 mm (4.0007-4.0017 in.)
Stroke 92.0 mm (3.622 in.)
Compression Ratio 9.67:1
Block
Camshaft Bearing Bore 1 and 5 Diameter 59.58-59.63 mm (2.345-2.347 in.)
Camshaft Bearing Bore 2 and 4 Diameter 59.08-59.13 mm (2.325-2.327 in.)
Camshaft Bearing Bore 3 Diameter 58.58-58.63 mm (2.306-2.308 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.)
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.)
Valve Lifter Bore Diameter 21.417-21.443 mm (0.843-0.844 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 0.004-0.008 mm (0.00015-0.0003 in.)
Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004-0.008 mm (0.00015-0.0003 in.)
Connecting Rod Side Clearance 0.11-0.51 mm (0.00433-0.02 in.)
Crankshaft
Connecting Rod Journal Diameter - Production 53.318 mm 53.338 mm (2.0991 in. 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 End Play 0.04 mm 0.2 mm (0.0015 in. 0.0078 in.)
Crankshaft Main Bearing Clearance - Production 0.02 mm 0.052 mm (0.0008 in. 0.0021 in.)
Crankshaft Main Bearing Clearance - Service 0.02 mm 0.065 mm (0.0008 in. 0.0025 in.)
Crankshaft Main Journal Diameter - Production 64.992 mm 65.008 mm (2.558 in. 2.559 in.)
Crankshaft Main Journal Diameter - Service 64.992 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 mm ( 26.22 mm (1.029 in.) 1.0315 in.)
Crankshaft Thrust Surface - Service 26.22 mm (1.0315 in.)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 in.)
Surface 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.)
Surface Flatness - Exhaust Manifold Deck 0.13 mm (0.005 in.)
Surface Flatness - Intake Manifold Deck 0.08 mm (0.0031 in.)
Piston Rings
Piston Ring End Gap - First Compression Ring (Measured in Cylinder Bore - Production) 0.20 mm 0.41 mm (0.008 in. 0.016 in.)
Piston Ring End Gap - First Compression Ring (Measured in Cylinder Bore - Service) 0.20 mm 0.41 mm (0.008 in. 0.016 in.)
Piston Ring End Gap - Second Compression Ring (Measured in Cylinder Bore - Production) 0.37 mm 0.69 mm (0.015 in. 0.027 in.)
Piston Ring End Gap - Second Compression Ring (Measured in Cylinder Bore - Service) 0.37 mm 0.69 mm (0.015 in. 0.027 in.)
Piston Ring End Gap - Oil Control Ring (Measured in Cylinder Bore - Production) 0.22 mm 0.79 mm (0.009 in. 0.031 in.)
Piston Ring End Gap - Oil Control Ring (Measured in Cylinder Bore - Service) 0.22 mm 0.79 mm (0.009 in. 0.031 in.)
Piston Ring to Groove Clearance - First Compression Ring - Production 0.030 mm 0.10 mm (0.0012 in. 0.0040 in.)
Piston Ring to Groove Clearance - First Compression Ring - Service 0.030 mm 0.10 mm (0.0012 in.)0.0040 in.)
Piston Ring to Groove Clearance - Second Compression Ring - Production 0.035 mm 0.078 mm (0.0014 in. 0.0031 in.)
Piston Ring to Groove Clearance - Second Compression Ring - Service 0.035 mm 0.078 mm (0.0014 in. 0.0031 in.)
Piston Ring to Groove Clearance - Oil Control Ring - Production 0.013 mm 0.201 mm (0.0005 in. 0.0079 in.)
Piston Ring to Groove Clearance - Oil Control Ring - Service 0.013 mm 0.201 mm (0.0005 in. 0.0079 in.)
Pistons and Pins
Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.002 mm 0.01 mm (0.0008 in. 0.0004 in.)
Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.002 mm 0.015 mm (0.0008 in. 0.0006 in.)
Pin - Piston Pin Diameter 23.952 mm 23.955 mm (0.943 in. 0.943 in.)
Pin - Piston Pin Fit in Connecting Rod Bore - Production 0.007 mm 0.02 mm (0.00027 in. 0.00078 in.)
Pin - Piston Pin Fit in Connecting Rod Bore - Service 0.007 mm 0.022 mm (0.00027 in. 0.00086 in.)
Piston - Piston Diameter - Measured Over Skirt Coating 101.611 mm 101.642 mm (4.0 in. 4.001 in.)
Piston - Piston to Bore Clearance - Production -0.022 mm 0.08 mm (-0.0009 in. 0.0012 in.)
Piston - Piston to Bore Clearance (Service Limit with Skirt Coating Worn Off) 0.024 mm 0.08 mm (0.00094 in. 0.0031 in.)
Crankshaft Balancer Retaining Bolt
Installation Pass to Ensure the Balancer is Completely Installed 330 Nm (240 lb ft.)
First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes 50 Nm (37 lb ft.)
Final Pass 140 °
Overhaul
Crankshaft Bearing Cap M8 Bolts 25 Nm (18 lb ft.)
Crankshaft Bearing Cap M10 Bolts
First Pass 20 Nm (15 lb ft.)
Final Pass 80 °
Crankshaft Bearing Cap M10 Studs
First Pass 20 Nm (15 lb ft.)
Final Pass 51 °
Overhaul

*1 Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface

*2 Measured at Gasket Sealing Surfaces and Measured Within a 200 mm (7.87 in) Area that Includes 2 Runner Port Openings

*3 Measured from the Spring Seat Surface to the Top of the Guide