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 - M10 Bolts
First Pass in Sequence 20 Nm (15 ft. lbs.)
Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap - M8 Bolts 25 Nm (18 ft. lbs.)
Crankshaft Bearing Cap - M10 Studs
First Pass in Sequence 20 Nm (15 ft. lbs.)
Crankshaft Bearing Cap - M10 Studs
Final Pass in Sequence 53 degrees
Engine Block Coolant Drain Hole Plug 60 Nm (44 ft. lbs.)
Engine Block Coolant Heater 40 Nm (30 ft. lbs.)
Engine Block Oil Gallery Plugs 60 Nm (44 ft. lbs.)
* Bore 99.0-99.018 mm (3.897-3.898 inch)
* Stroke 92.0 mm (3.622 inch)
* Compression Ratio 10.5:1
Crankshaft Main Bearing
Bore Diameter 69.871-69.889 mm (2.75-2.751 inch)
Bore Out-of-Round 0.005 mm (0.0002 inch)
Cylinder Bore Diameter 99.0-99.018 mm (3.897-3.898 inch)
Connecting Rod
Connecting Rod Bearing Clearance
Production 0.023-0.065 mm (0.0009-0.0025 inch)
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 0.006 mm (0.00023 inch)
Connecting Rod Bore Out-of-Round - Bearing End - Service 0.006 mm (0.00023 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)
Service 53.308 mm (2.0987 inch)
Connecting Rod Journal Out-of-Round
Production 0.005 mm (0.0002 inch)
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)
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)
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)
Service 64.992 mm (2.558 inch)
Crankshaft Main Journal Out-of-Round
Production (0.003 mm (0.000118 inch)
Service 0.008 mm (0.0003 inch)
Crankshaft Main Journal Taper -
Production 0.01 mm (0.0004 inch)
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)
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 0.23-0.44 mm (0.009-0.017 inch)
Service 0.23-0.5 mm (0.009-0.0196 inch)
Piston Ring End Gap -
Second Compression Ring - Measured in Cylinder Bore -
Production 0.44-0.7 mm (0.017-0.027 inch)
Service 0.44-0.76 mm (0.0173-0.03 inch)
Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore -
Production 0.18-0.75 mm (0.007-0.029 inch)
Service 0.18-0.81 mm (0.007-0.032 inch)
Piston Ring to Groove Clearance - First Compression Ring -
Production 0.04-0.086 mm (0.00157-0.0033 inch)
Service 0.04-0.068 mm (0.00157-0.0033 inch)
Piston Ring to Groove Clearance - Second Compression Ring -
Production 0.05-0.088 mm (0.002-0.0034 inch)
Service 0.05-0.088 mm (0.002-0.0034 inch)
Piston Ring to Groove Clearance - Oil Control Ring -
Production -0.008 to +0.0176 mm (-0.0003 to +0.0069 inch)
Service -0.008 to +0.0176 mm (-0.0003 to +0.0069 inch)
Pistons and Pins
Pin - Piston Pin Clearance to Piston Pin Bore -
Production 0.002-0.01 mm (0.00008-0.0004 inch)
Service 0.002-0.015 mm (0.00008-0.0006 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)
Service 0.007-0.022 mm (0.00027-0.00086 inch)
Piston - Piston Diameter - Measured Over Skirt Coating 98.984-99.027 mm (3.897-3.899 inch)
Piston - Piston to Bore Clearance - Coated Skirt -
Production -0.027 to +0.029 mm (-0.001 to +0.0011 inch)
Piston - Piston to Bore Clearance - Coating Worn Off -
Service Limit 0.074 mm (0.0029 inch)