System Specifications

Cylinder Head Deck Surface Flatness - Overall 0.0762 mm (0.003 inch)
Cylinder Bore Diameter 98.5 mm (3.8 inch)
Cylinder Bore Out-of-Round - Diametral 0.0254 mm (0.001 inch)
Cylinder Bore Taper 0.0254 mm (0.001 inch)
Crankshaft Main Journal Diameter 63.470-63.495 mm (2.4988-2.4998 inch)
Crankshaft Main Journal Out-of-Round 0.00635 mm (0.00025 inch)
Crankshaft Main Journal Taper 0.00889 mm (0.002 inch)
Crankshaft Rear Flange Runout 0.05 mm (0.002 inch)
Crankshaft Runout - from Main 2 & 3 to 1 & 4 0.076 mm (0.003 inch)
Crankshaft Main Bearing Clearance - # 1 0.0178-0.0406 mm (0.0007-0.0016 inch)
Crankshaft Main Bearing Clearance - # 2, 3 and 4 0.0229-0.0457 mm (0.0009-0.0018 inch)
Crankshaft Main Journal Diameter 63.470-63.495 mm (2.4988-2.4998 inch)

Main Bearing Cap Service and Repair

Connecting Rod Side Clearance 0.102-0.508 mm (0.004-0.0200 inch)
Connecting Rod Bearing Clearance 0.0127-0.0660 mm (0.0005-0.0026 inch)

Piston Diameter
Production - S/C 96.489-96.528 mm (3.7988-3.8003 inch)
Production - Non S/C 96.482-96.497 mm (3.7985-3.7991 inch)
Service Limit- Minimum - S/C 96.434 mm (3.7966 inch)
Service Limit - Minimum - Non S/C 96.442 mm (3.7969 inch)
Piston to Bore Clearance
New - VIN K 0.010-0.051 mm (0.0004-0.0020 inch)
Used - VIN K 0.050-0.091 mm (0.0020-0.0036 inch)
New - VIN 1 -0.0207-0.0437 mm (-0.0008-0.0018 inch)
Used VIN 1 0.0193-0.0997 mm (0.0008-0.0039 inch)
Piston Ring End Gap
First Compression Ring 0.25-0.46 mm (0.010-0.018 inch)
Second Compression Ring 0.58-0 84 mm (0.023-0.033 inch)
Oil Control Ring 0.254-0.762 mm (0.010-0 030 inch)
Piston Ring to Groove Clearance
First Compression Ring 0.033-0.079 mm (0.0013-0 0031 inch)
Second Compression Ring 40 033-0.079 mm (0.0013-0 0031 inch)
Piston Ring Thickness
First Compression Ring 1.176-1.197 mm (0.0463-0.0471 inch)
Second Compression Ring 1.1476-1.497 mm (0.0581-0 0589 inch)

Crankshaft Balancer Bolt
First Pass 150 Nm (111 lb ft)
Final Pass 76 degrees