System Specifications

HEAD SET BOLT






SURFACE VARIATION





MAIN BEARING CAP

(a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.





(b) Install the 5 crankshaft bearing caps in their proper locations.





(c) Install the crankshaft bearing cap bolts.

HINT: The main bearing cap bolts are tightened in 2 progressive steps.

(d) Step 1
(1) Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)

If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.





(e) Step 2
(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts by 90° in the order above.
(3) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance.

Each bearing's standard thickness is indicated by a 1, 2 or 3 mark on its
surface.

Reference:

Cylinder block main journal bore diameter






Standard bearing center wall thickness






CRANKSHAFT










CRANKSHAFT TIMING GEAR OR SPROCKET

Minimum distance 1.0 mm (0.039 in.)

Minimum sprocket diameter (with chain) 59.4 mm (2.338 in.)

NO. 2 CRANKSHAFT TIMING SPROCKET

Minimum sprocket diameter (with chain) 96.7 mm (3.807 in.)

CRANKSHAFT BEARING CAP SET BOLT

Standard diameter 10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum diameter 10.66 mm (0.4197 in.)

PISTON SUB-ASSEMBLY WITH CONNECTING ROD

- Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.





- Position the piston rings so that the ring ends are as shown in the illustration.
CAUTION: Do not align the ring ends.





- Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
- Match the numbered connecting rod cap with the connecting rod.

NOTICE: Match the numbered connecting rod cap with the connecting rod.





- Check that the front mark of the connecting rod cap is facing forward.
- Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.





- Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)





- Mark the front side of each connecting cap bolt with paint.
- Retighten the cap bolts by 90° as shown.
- Check that the painted mark is now at a 90° angle to the front.
- Check that the crankshaft turns smoothly.
- Check the connecting rod thrust clearance.


CONNECTING ROD





CONNECTING ROD BOLT

Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter 7.0 mm (0.276 in.)

There are 4 sizes of standard bearings, marked "1 ", "2", "3" and "4"
accordingly.

Standard bearing center wall thickness









PISTON





PISTON RING





CRANKSHAFT PULLEY

Torque 260 Nm (2,650 kgf-cm, 192ft-lbf)