Cylinder Block Assembly: Specifications

Cylinder Block Assembly
Cylinder bore 76.50 - 76.53 mm (3.0118 - 3.0130 inch)
Out-of-round and taper of cylinder bore Less than 0.01 mm (0.0004 inch)
Clearance with piston 0.025 - 0.045 mm (0.0009 - 0.0017 inch)

PISTON:

Piston
OR 76.465 - 76.495 mm (3.0104 - 3.0116 inch)
Service size 0.25 mm (0.010 inch) oversize

Piston ring
Side clearance
No. 1
Standard 0.04 - 0.085 mm (0.0015 - 0.0033 inch)
Limit 0.1 mm (0.004 inch)

No. 2
Standard 0.04 - 0.085 mm (0.0015 - 0.0033 inch)
Limit 0.1 mm (0.004 inch)

End gap
No. 1
Standard 0.15 - 0.30 mm (0.0059 - 0.012 inch)
Limit 1.0 mm (0.039 inch)

No. 2
Standard 0.30 - 0.45 mm (0.012 - 0.0177 inch)
Limit 1.0 mm (0.039 inch)

Oil ring side rail
Standard 0.2 - 0.7 mm (0.0078 - 0.0275 inch)
Limit 1.0 mm (0.039 inch)

Service size 0.25 mm (0.010 inch) oversize

Connecting rod
Bend 0.05 mm (0.0020 inch) or less
Twist 0.1 mm (0.0039 inch) or less

Connecting rod big end to crankshaft side clearance
Standard 0.100-0.250 mm (0.0039-0.0098 inch)
Limit 0.4 mm (0.0157in.)

Connecting rod bearing oil clearance 0.018-0.036 mm (0.0007-0.0014 inch)
Undersize 0.25, 0.50, 0.75 mm (0.010, 0.020, 0.030 inch)

CRANKSHAFT:

CRANKSHAFT MAIN JOURNAL DIAMETER:

MAIN JOURNAL BEARING THICKNESS / NO 1 2 4 5 (MAIN BEARING):

MAIN JOURNAL BEARING THICKNESS / NO.3 (CENTER BEARING):

Crankshaft
Pin O.D. 45 mm (1.77 inch)
Journal O.D. 50 mm (1.97 inch)
Bend 0.03 mm (0.0012 inch) or less

Out-of-round, taper of journal and pin 0.005 mm (0.0002 inch) or less
End play 0.05-0.175 mm (0.0019-0.0068 inch)

Undersize rework dimension of pin
0.25 mm (0.010 inch) 44.725 - 44.74 mm (1.7608 - 1.7614 inch)
0.50 mm (0.020 inch) 44.475 - 44.49 mm (1.7509 - 1.7516 inch)
0.75 mm (0.030 inch) 44.225 - 44.24 mm (1.7411 - 1.7417 inch)

Undersize rework dimension of journal
0.25 mm (0.010 inch) 49.727 - 49.742 mm (1.9577 - 1.9583 inch)
0.50 mm (0.020 inch) 49.477 - 49.492 mm (1.9479 - 1.9485 inch)
0.75 mm (0.030 inch) 49.227 - 49.242 mm (1.9380 - 1.9386 inch)



TIGHTENING TORQUE
Front engine support bracket bolt and nut 45-55 Nm (450-550 kg-cm, 33-41 ft. lbs.)
Engine support bracket stay bolt 45-55 Nm (450-550 kg-cm, 33-41 ft. lbs.)
Oil pressure switch 13-15 Nm (130-150 kg-cm, 10-11 ft. lbs.)
Connecting rod cap nut 32 - 35 Nm (320 - 350 kg-cm, 24 - 26 ft. lbs.)
Surge tank stay to cylinder block bolts 18-25 Nm (180-250 kg-cm, 13-18 ft. lbs.)
Crankshaft Pulley bolt 140-150 Nm (1400-1500 Kg.cm, 103-111 ft. lbs.)




Crankshaft bearing cap bolt 55 - 60 Nm (550 - 600 kg-cm, 41 - 44 ft. lbs.)

* Install bearing caps and tighten cap bolts to the specified torque in the following sequence; center, No.2, No.4, front, and rear caps.
* Cap bolts should be tightened evenly in 2 to 3 stages before they are tightened to the specified torque.







* The caps should be installed with the arrow mark directed toward the crank pulley side of engine. Cap numbers must be correct.