System Specifications
Cylinder BlockWarpage
Maximum 0.07 mm (0.0028 inch)
Bore diameter
Standard 94.000 to 94.012 mm (3.7008 to 3.7013 inch)
Maximum 94.200 mm (3.7087 inch)
Crankshaft position sensor x Cylinder block 10 Nm (102 kgf-cm, 7 ft. lbs.)
Knock sensor x Cylinder block sub-assembly 20 Nm (204 kgf-cm, 15 ft. lbs.)
V-ribbed belt tensioner x Cylinder block 43 Nm (438 kgf-cm, 32 ft. lbs.)
Drive shaft bearing bracket x Cylinder block 64 Nm (653 kgf-cm, 47 ft. lbs.)
No. 1 oil dipstick guide x Cylinder block 21 Nm (214 kgf-cm, 15 ft. lbs.)
Connecting rod
Thrust clearance
Standard 0.15 to 0.40 mm (0.0059 to 0.0157 inch)
Maximum 0.50 mm (0.0197 inch)
Oil clearance
Standard 0.045 to 0.067 mm (0.0018 to 0.0026 inch)
Maximum 0.070 mm (0.0028 inch)
Big end inside diameter
Mark 1 56.000 to 56.006 mm (2.2047 to 2.2050 inch)
Mark 2 56.007 to 56.012 mm (2.2050 to 2.2052 inch)
Mark 3 56.013 to 56.018 mm (2.2052 to 2.2054 inch)
Mark 4 56.019 to 56.024 mm (2.2055 to 2.2057 inch)
Standard sized bearing center wall thickness
Mark 1 1.481 to 1.484 mm (0.0583 to 0.0584 inch)
Mark 2 1.484 to 1.497 mm (0.0584 to 0.0589 inch)
Mark 3 1.487 to 1.490 mm (0.0585 to 0.0587 inch)
Mark 4 1.490 to 1.493 mm (0.0587 to 0.0588 inch)
Bend
Maximum 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
Twist
Maximum 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
Crankshaft
Pin diameter
Standard 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
Thrust clearance
Standard 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum 0.30 mm (0.0118 inch)
Thrust washer thickness
Standard 2.43 to 2.48 mm (0.0957 to 0.0976 inch)
Main journal diameter
Standard
Mark 00 60.999 to 61.000 mm (2.4015 to 2.4016 inch)
Mark 01 60.998 to 60.999 mm (2.4015 to 2.4015 inch)
Mark 02 60.997 to 60.998 mm (2.4015 to 2.4015 inch)
Mark 03 60.996 to 60.997 mm (2.4014 to 2.4015 inch)
Mark 04 60.995 to 60.996 mm (2.4014 to 2.4014 inch)
Mark 05 60.994 to 60.995 mm (2.4013 to 2.4014 inch)
Mark 06 60.993 to 60.994 mm (2.4013 to 2.4013 inch)
Mark 07 60.992 to 60.993 mm (2.4013 to 2.4013 inch)
Mark 08 60.991 to 60.992 mm (2.4012 to 2.4013 inch)
Mark 09 60.990 to 60.991 mm (2.4012 to 2.4012 inch)
Mark 10 60.989 to 60.990 mm (2.4011 to 2.4012 inch)
Mark 11 60.988 to 60.989 mm (2.4011 to 2.4011 inch)
Upper bearing center wall thickness
Standard No. 1 and No. 4 journal
Mark 1 2.500 to 2.503 mm (0.0984 to 0.0985 inch)
Mark 2 2.503 to 2.506 mm (0.0985 to 0.0987 inch)
Mark 3 2.506 to 2.509 mm (0.0987 to 0.0988 inch)
Mark 4 2.509 to 2.512 mm (0.0988 to 0.0989 inch)
Mark 5 2.512 to 2.515 mm (0.0989 to 0.0990 inch)
Standard No. 2 and No. 3 journal
Mark 1 2.478 to 2.481 mm (0.0976 to 0.0977 inch)
Mark 2 2.481 to 2.484 mm (0.0977 to 0.0978 inch)
Mark 3 2.484 to 2.487 mm (0.0978 to 0.0979 inch)
Mark 4 2.487 to 2.490 mm (0.0979 to 0.0980 inch)
Mark 5 2.490 to 2.493 mm (0.0980 to 0.0981 inch)
Lower bearing center wall thickness
Standard No. 1 and No. 4 journal
Mark 1 2.478 to 2.481 mm (0.0976 to 0.0977 inch)
Mark 2 2.481 to 2.484 mm (0.0977 to 0.0978 inch)
Mark 3 2.484 to 2.487 mm (0.0978 to 0.0979 inch)
Mark 4 2.487 to 2.490 mm (0.0979 to 0.0980 inch)
Mark 5 2.490 to 2.493 mm (0.0980 to 0.0981 inch)
Standard No. 2 and No. 3 journal
Mark 1 2.500 to 2.503 mm (0.0984 to 0.0985 inch)
Mark 2 2.503 to 2.506 mm (0.0985 to 0.0987 inch)
Mark 3 2.506 to 2.509 mm (0.0987 to 0.0988 inch)
Mark 4 2.509 to 2.512 mm (0.0988 to 0.0989 inch)
Mark 5 2.512 to 2.515 mm (0.0989 to 0.0990 inch)
Circle runout
Maximum 0.06 mm (0.0024 inch)
Journal diameter
Standard 60.988 to 61.00 mm (2.4011 to 2.4016 inch)
Taper and out-of-round
Maximum 0.02 mm (0.0008 inch)
Crank pin diameter
Standard 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
Taper and out-of-round
Maximum Taper and out-of-round 0.02 mm (0.0008 inch)
Piston
Diameter
Standard 93.960 to 93.980 mm (3.6992 to 3.6999 inch)
Maximum 93.830 mm (3.6941 inch)
Distance 9.8 mm (0.3858 inch)
Oil clearance
Standard 0.020 to 0.052 mm (0.0008 to 0.0020 inch)
Maximum 0.06 mm (0.0024 inch)
Ring groove clearance
Standard
No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 inch)
No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 inch)
Oil 0.070 to 0.150 mm (0.0028 to 0.0059 inch)
Ring end gap
Standard
No. 1 0.25 to 0.35 mm (0.0098 to 0.0138 inch)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 inch)
Oil 0.10 to 0.40 mm (0.0039 to 0.0157 inch)
Maximum
No. 1 0.50 mm (0.0197 inch)
No. 2 0.85 mm (0.0335 inch)
Oil 0.60 mm (0.0236 inch)
Piston pin hole inside diameter
Standard
Mark A 22.001 to 22.004 mm (0.8662 to 0.8663 inch)
Mark B 22.005 to 22.007 mm (0.8663 to 0.8664 inch)
Mark C 22.008 to 22.010 mm (0.8665 to 0.8665 inch)
Piston pin diameter
Standard
Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 inch)
Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 inch)
Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 inch)
Oil clearance
Standard 0.001 to 0.007 mm (0.00004 to 0.0003 inch)
Maximum 0.015 mm (0.0006 inch)
Bush inside diameter
Standard
Mark A 22.005 to 22.008 mm (0.8663 to 0.8665 inch)
Mark B 22.009 to 22.011 mm (0.8665 to 0.8666 inch)
Mark C 22.012 to 22.014 mm (0.8666 to 0.8667 inch)
Oil clearance
Standard 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum 0.03 mm (0.0012 inch)
Crankshaft bearing cap set bolt
Diameter
Standard 10.8 to 11.0 mm (0.4252 to 0.4331 inch)
Minimum 10.70 mm (0.4213 inch)
Connecting rod bolt
Diameter
Standard 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum 7.0 mm (0.276 inch)
Crankshaft Pulley
Torque 250 Nm (2,549 kgf-cm, 184 ft. lbs.)
Main Bearing Cap
Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block.
Temporarily install the 8 main bearing cap bolts to the inside positions.
Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 inch) by marking the 2 internal bearing cap bolts as a guide.
Bolt length 100.0 to 102.0 mm (3.937 to 4.016 inch)
Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
Install the 8 main bearing cap bolts to the outside positions.
Bolt length 105.5 to 107.5 mm (4.154 to 4.232 inch)
Install the crankshaft bearing cap bolts.
HINT: The main bearing cap bolts are tightened in 2 progressive steps.
Step 1
Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque 61 Nm (622 kgf-cm, 45 ft. lbs.)
If any of the main bearing cap bolts does not meet the specified torque, replace it.
Step 2
Mark the front of the bearing cap bolts with paint.
Tighten the bearing cap bolts another 90° in the order shown in step 1.
Check that the painted mark is now at a 90° angle to the front.
Check that the crankshaft turns smoothly.
Install and uniformly tighten the 8 main bearing cap bolts in several steps, in the sequence shown in the illustration.
Torque 52 Nm (530 kgf-cm, 38 ft. lbs.)
Bolt length
bolt A 45 mm (1.77 inch)
except bolt A 30 mm (1.18 inch)
Check that the crankshaft turns smoothly.
Crankshaft Pulley
Torque 250 Nm (2,549 kgf-cm, 184 ft. lbs.)