System Specifications
MAIN BEARING CAP TORQUE
M10 Bolts (1-10) In Sequence
- First Pass 20 N.m (15 lb ft)
Important: To properly align the crankshaft thrust bearings, the final thrust of the crankshaft MUST be in the forward direction.
Using a plastic-face hammer, tap the crankshaft rearward, then forward in order to align the thrust bearings.
- Final Pass 80 degrees using the J 45059
M10 studs (11-20) in sequence
- First Pass 20 N.m (15 lb ft)
- Final Pass 51 degrees using the J 45059
Bearing Cap Side M8 Bolts. Tighten the bolt on 1 side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap.
- Bearing Cap Side M8 Bolts 25 N.m (18 lb ft)
CRANKSHAFT PULLEY TORQUE
Tighten The Crankshaft Balancer Bolt 330 N.m (240 lb ft)
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 103.241-103.259 mm (4.065-4.065 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)
CAMSHAFT
Camshaft End Play 0.025-0.305 mm (0.001-0.012 in)
Camshaft Journal Diameter 54.99-55.04 mm (2.164-2.166 in)
Camshaft Journal Out-of-Round 0.025 mm (0.001 in)
Camshaft Lobe Lift
Exhaust 7.48 mm (0.294 in)
Camshaft Lobe Lift
Intake 7.48 mm (0.294 in)
Camshaft Runout
Measured at the Intermediate Journals 0.05 mm (0.002 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 53.318-53.338 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 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 64.992-65.008 mm (2.558-2.559 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 26.14-26.22 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)
CYLINDER HEAD
Cylinder Head Height/Thickness
Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface 120.2 mm (4.732 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)
Valve Guide Installed Height
Measured from the Spring Seat Surface to the Top of the Guide 17.32 mm (0.682 in)
INTAKE MANIFOLD
Surface Flatness
Measured at Gasket Sealing Surfaces and Measured Within a 200 mm (7.87 in) Area that Includes 2 Runner Port Openings 0.3 mm (0.118 in)
PISTON RINGS
Piston Ring End Gap - First Compression Ring
Measured in Cylinder Bore - Production 0.23-0.44 mm (0.009-0.017 in)
Piston Ring End Gap - First Compression Ring
Measured in Cylinder Bore - Service 0.23-0.5 mm (0.009-0.0196 in)
Piston Ring End Gap - Second Compression Ring
Measured in Cylinder Bore - Production 0.44-0.7 mm (0.017-0.027 in)
Piston Ring End Gap - Second Compression Ring
Measured in Cylinder Bore - Service 0.44-0.76 mm (0.0173-0.03 in)
Piston Ring End Gap - Oil Control Ring
Measured in Cylinder Bore - Production 0.18-0.75 mm (0.007-0.029 in)
Piston Ring End Gap - Oil Control Ring
Measured in Cylinder Bore - Service 0.18-0.81 mm (0.007-0.032 in)
Piston Ring-to-Groove Clearance - First Compression Ring
Production 0.04-0.085 mm (0.00157-0.00335 in)
Piston Ring-to-Groove Clearance - First Compression Ring
Service 0.04-0.085 mm (0.00157-0.00335 in)
Piston Ring-to-Groove Clearance - Second Compression Ring
Production 0.04-0.078 mm (0.00157-0.0031 in)
Piston Ring-to-Groove Clearance - Second Compression Ring
Service 0.04-0.078 mm (0.00157-0.0031 in)
Piston Ring-to-Groove Clearance - Oil Control Ring
Production 0.012-0.2 mm (0.0005-0.0078 in)
Piston Ring-to-Groove Clearance - Oil Control Ring
Service 0.012-0.2 mm (0.0005-0.0078 in)
PISTONS AND PINS
Pin - Piston Pin Clearance-to-Piston Pin Bore
Production 0.002-0.01 mm (0.00008-0.0004 in)
Pin - Piston Pin Clearance-to-Piston Pin Bore
Service 0.002-0.015 mm (0.00008-0.0006 in)
Pin - Piston Pin Diameter 23.952-23.955 mm (0.943-0.943 in)
Pin - Piston Pin Fit in Connecting Rod Bore
Production 0.007-0.02 mm (0.00027-0.00078 in)
Pin - Piston Pin Fit in Connecting Rod Bore
Service 0.007-0.022 mm (0.00027-0.00086 in)
Piston - Piston Diameter
Measured Over Coating 96.002-96.036 mm (3.779-3.78 in)
Piston - Piston to Bore Clearance
Production -0.036 to +0.016 mm (-0.0014 to +0.0006 in)
Piston - Piston to Bore Clearance
Service Limit With Skirt Coating Worn Off 0.071 mm (0.0028 in)