System Specifications
SURFACE VARIATIONFlatness 0.019 mm (0.00075 in.)
CYLINDER BORE
Cylinder Bore Diameter 102.993 - 103.007 mm (4.05484 - 4.05539 in.)
Out of Round (MAX) 0.008 mm (0.0003 in.)
Taper (MAX) 0.015 mm (0.0006 in.)
CRANKSHAFT
Out-of-Round (Max.) 0.005 mm (0.0002 in.)
Taper (MAX) 0.005 mm (0.0002 in.)
End Play 0.101 - 0.228 mm (0.0040 - 0.0090 in.)
Wear Limit 0.280 mm (0.011 in.)
Connecting Rod Journal Diameter 53.993 - 54.008 mm (2.1261 - 2.1263 in.)
MAIN BEARING
Main Bearing Bore 81.087 - 81.100 mm (3.1923 - 3.1929 in.)
Main Bearing Clearance 1-6 0.0381 - 0.0635 mm (0.0015 - 0.0025 in.)
Wear Limit 0.075 mm (0.003 in.)
MAIN BEARING CAP
Install each main bearing cap in proper sequence and direction. Tighten all bolts finger tight.
Tighten main bearing cap bolts 1-12 to 20 Nm (15 ft. lbs.).
Tighten main bearing cap bolts 1-12 to 27 Nm (20 ft. lbs.).
Tighten main bearing cap bolts 1-12 to 54 Nm (40 ft. lbs.).
Rotate main bearing cap bolts an additional 50°.
Tighten main bearing cap side bolts 1-12 to 13 Nm (115 in. lbs.).
Tighten main bearing cap side bolts 1-12 to 27 Nm (20 ft. lbs.).
Rotate main bearing cap side bolts 1-12 an additional 45°.
MAIN BEARING JOURNALS
Diameter 76.233 - 76.253 mm (3.0013 - 3.0021 in.)
Out of Round (Max.) 0.005 mm (0.0002 in.)
CONNECTING RODS
Bearing Clearance 0.0381 - 0.0559 mm (0.0015 - 0.0022 in.)
Wear Limit 0.080 mm (0.0031 in.)
Side Clearance (Two Rods) 0.071 - 0.369 mm ( 0.0028 - 0.0145 in.)
Total Weight (Less Bearing) 649.7 grams (22.92 oz)
Piston Pin Clearance In Connecting Rod 0.007 - 0.020 mm (0.00027 - 0.00079 in.)
Piston Pin Wear Limit 0.025 mm (0.0009 in.)
PISTONS
Piston Size (Over Coating) 102.976 - 103.008 mm (4.0542 - 4.0551 in.)
Weight 431.5 - 441.5 grams (15.22 - 15.57 oz.)
Piston Length 55.0 mm (2.165 in.)
Piston Pin Clearance in Piston 0.006 - 0.015 mm (0.00023 - 0.00059 in.)
Piston Pin Wear Limit 0.020 mm (0.0007 in.)
Piston Pin Bore Diameter 25.009 - 25.015 mm (0.9846 - 0.9848 in.)
Piston Pin Bore Offset 0.800 mm (0.031 in.)
Piston Ring Groove Inner Diameter No. 1 93.10 - 93.30 mm (3.665 - 3.673 in.)
Piston Ring Groove Inner Diameter No. 2 91.60 - 91.80 mm (3.6063 - 3.6142 in.)
Piston Ring Groove Inner Diameter No. 3 95.80 - 96.00 mm (3.7717 - 3.7795 in.)
PISTON RINGS
Piston Ring Gap:
Top Compression Ring 0.30 - 0.45 mm (0.0118 - 0.0177 in.)
Second Compression Ring 0.65 - 0.90 mm (0.0256 - 0.0354 in.)
Oil Control (Steel Rails) 0.20 - 0.71 mm (0.00787 - 0.02795 in.)
Wear Limit - Top Compression Ring 0.68 mm (0.027 in.)
Wear Limit - 2nd Compression Ring 1.50 mm (0.059 in.)
Wear Limit - Oil Control Steel Rails 1.50 mm (0.059 in.)
Piston Ring Side Clearance:
Top Compression Ring 0.020 - 0.068 mm (0.0078 - 0.00267 in.)
2nd Compression Ring 0.020 - 0.058 mm (0.0078 - 0.00228 in.)
Oil Rings 0.012 - 0.178 mm (0.0005 - 0.0070 in.)
Wear Limit - Top and 2nd Ring 0.080 mm (0.003 in.)
Wear Limit Oil Ring Pack 0.200 mm (0.0078 in.)
CRANKSHAFT PULLEY
Crankshaft Damper Bolt 339 Nm (250 ft. lbs.).
Crankshaft Pulley Bolts 23 Nm (17 ft. lbs.)