Cylinder Block Assembly: Specifications

Installing crankshaft bearing cap
^ Replace bolts A and nuts -1- to -8-.
^ Inserting alignment bushings into cylinder block
^ Tighten bearing cap nuts or bolts in the following sequence:
1. - Screw in bolts -A- hand tight.
2. - Tighten nuts -1- to -8- to 35 Nm.
3. - Tighten nuts -1- to -8- 90° (1/4 turn) further using rigid wrench.
4. - tighten bolts -A- to 20 Nm.
5. - Tighten bolts -A- 90° (1/4 turn) further using rigid wrench.

Connecting rod bolt 30 Nm + 90° (1/4 additional turn)

Harmonic balancer to crankshaft 23 Nm
Vibration damper/pulley at crankshaft 10 Nm + 90° 2)3)
2) Replace bolts
3) 90° equals one quarter turn








Checking piston ring end gap
^ Insert ring at a right angle to cylinder wall from above to lower cylinder opening approximately 15 mm cylinder edge. When inserting use pistons without rings








Checking piston ring side clearance
^ Before measuring] clean piston ring groove

Checking pistons
Special Tools and Equipment





^ External micrometer 75-100 mm
^ Measure approximately 10 mm from the lower edge at a 90° angle to piston pin axis.
^ Deviation from nominal dimension: maximum 0.04 mm
Specified dimension, Refer to Piston piston and cylinder measurements





Piston installed position and allocation piston/cylinder
^ Mark installed position and allocation to cylinder on piston head using chalk or water-proof felt pen.

Note: Do not use a center punch or scribe, since the piston head coating will be damaged.

^ Installation position:
Arrow on piston head points to belt pulley side





Piston and cylinder measurements
1) Dimensions exclude graphite coating (thickness 0 02 mm). The graphite coating wears off.





Crankshaft measurements

Axial and Radial Play, Measuring
Axial Clearance
Clearance when new 0.07 to 0.23 mm
Wear limit 0.25 mm
Radial Clearance
Clearance when new 0.018 to 0.045 mm
Wear limit 0.08 mm

Connecting Rod
Clearance When new 0.015 ro 0.062 mm
Wear limit 0.12 mm