System Specifications

Connecting Rod Bolts
First Pass 25 Nm (18 ft. lbs.)
Final Pass 100°





Crankshaft Bearing Lower Crankcase to Block Bolts
First Pass 20 Nm (15 ft. lbs.)
Final Pass 70° using the J 36660-A (SA9140E)





Tighten the lower crankcase perimeter bolts to 25 Nm (18 ft. lbs.)

Crankshaft Pulley Bolt
First Pass 100 Nm (74 ft. lbs.)
Final Pass 125°

Balance Shaft
Bearing Clearance 0.030-0.063 mm (0.0012-0.0025 inch)
Bearing Diameter - Inside - Carrier 20.050-20.063 mm (0.7894-0.7899 inch)
Bearing Diameter - Outside - Carrier 41.975-41.995 mm (1.6526-1.6534 inch)
Bearing Journal Diameter 20.000-20.020 mm (0.7874-0.7882 inch)
Bushing Clearance 0.033-0.102 mm (0.0013-0.0040 inch)
Bushing Diameter - Inside 36.776-36.825 mm (1.4479-1.4498 inch)
Bushing Journal Diameter 36.723-36.743 mm (1.4458-1.4466 inch)
End Play 0.100-0.300 mm (0.0020-0.0118 inch)

Block
Balance Shaft Bearing Bore Diameter - Carrier 42.000-42.016 mm (1.6535-1,6542 inch)
Balance Shaft Bushing Bore Diameter 40.763-40.776 mm (1.6048-1.6054 inch)
Crankshaft Main Bearing Bore Diameter 64.068-64.082 mm (2.5224-2.5229 inch)
Cylinder Bore Diameter 85.992-86.008 mm (3.3855-3.3861 inch)
Cylinder Bore Out-of-Round - Maximum 0.010 mm (0.0004 inch)
Cylinder Bore Taper - Maximum 0.010 mm (0.0004 inch)
Cylinder Head Deck Surface Flatness - Transverse 0.030 mm (0.0012 inch)
Cylinder Head Deck Surface Flatness - Longitude 0.050 mm (0.002 inch)
Cylinder Head Deck Surface Flatness - Overall 0.08 mm (0.0031 inch)
Camshaft Camshaft End Play 0.040-0.144 mm (0.0016-0.0057 inch)
Camshaft Journal Diameter 26.935-26.960 mm (1.0604-1.0614 inch)
Camshaft Thrust Surface 21.000-21.052 mm (0.8268-0.8252 inch)
Connecting Rod Connecting Rod Bearing Clearance 0.029-0.069 mm (0.0011-0.0027 inch)
Connecting Rod Bore Diameter - Bearing End 52.118-52.134 mm (2.0519-2.05252 inch)
Connecting Rod Bore Diameter - Pin End 20.007-20.021 mm (0.7877-0.7882 inch)
Connecting Rod Side Clearance 0.070-0.370 mm (0.0028-0.0146 inch)
Connecting Rod Straightness - Bend - Maximum 0.021 mm (0.0083 inch)
Connecting Rod Straightness - Twist - Maximum 0.04 mm (0.0157 inch)

Crankshaft
Connecting Rod Journal Diameter 49.000-49.014 mm (1.9291-1.9297 inch)
Crankshaft End Play 0.050-0.380 mm (0.0012-0.0150 inch)
Crankshaft Main Bearing Clearance 0.031-0.067 mm (0.0012-0.0026 inch)
Crankshaft Main Journal Diameter 55.994-56.008 mm (2.2045-2.2050 inch)

Valve Guide Bore - Exhaust 6.000-6.012 mm (0.2362-0.2367 inch)
Valve Guide Bore - Intake 6.000-6.012 mm (0.2362-0.2367 inch)
Valve Lifter Bore Diameter - Stationary Lash Adjusters 12.013-12.037 mm (0.4730--0.4739 inch)

Piston Rings
Piston Ring End Gap - First Compression Ring 0.20-0.40 mm (0.008-0.016 inch)
Piston Ring End Gap - Second Compression Ring 0.35-0.55 mm (0.014-0.022 inch)
Piston Ring End Gap - Oil Control Ring - Rails 0.25-0.76 mm (0.010-0.030 inch)
Piston Ring to Groove Clearance - First Compression Ring 0.04-0.08 mm (0.0015--0-0031 inch)
Piston Ring to Groove Clearance - Second Compression Ring 0.030-0.069 mm (0.00 12-0.0027 inch)
Piston Ring to Groove Clearance - Oil Control Ring 0.090-0.106 mm (0.0035-0.0042 inch)
Piston Ring Thickness - First Compression Ring 1.170-1.190 mm (0.0461-0.0469 inch)
Piston Ring Thickness - Second Compression Ring 1.471-1.490 mm (0.0579-0.0587 inch)
Piston Ring Thickness - Oil Control Ring - Rail - Maximum 0.43 mm (0.0169 inch)
Piston Ring Thickness - Oil Control Ring - Spacer 1.574-1.651 mm (0.0620--0.0650 inch)
Pistons and Pins Piston - Piston Diameter - @ 14.5 mm (up 85.967-85.982 mm (3.3845-3.3851 inch)
Piston - Piston Pin Bore Diameter 20.002-20.007 mm (0.07875-0.7877 inch)
Piston - Piston Ring Grove Width - Top 1.23-1.25 mm (0.0484-0.0492 inch)
Piston - Piston Ring Grove Width - Second 1.52-1.54 mm (0.0598-0-0606 inch)
Piston - Piston Ring Grove Width - Oil Control 2.52-2.54 mm (0.0992-0.1000 inch)
Piston - Piston To Bore Clearance 0.010-0.041 mm (0.0004-0.0016 inch)
Pin - Piston Pin Clearance to Connecting Rod Bore 0.007-0.026 mm (0.0003-0.0010 inch)
Pin - Piston Pin Clearance to Piston Pin Bore 0.002-0.012 mm (0.0001-0.0005 inch)
Pin - Piston Pin Diameter 19.995-20.000 mm (0.7872-0.7874 inch)
Pin - Piston Pin End Play 0.19-1.16 mm (0.0075-0.0461 inch)