General Specifications
SPECIFICATIONSPart 1:
Part 2:
Part 3:
Part 4:
Part 5:
NOTE: STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
Part 1:
Part 2:
Timing Belt
Cylinder head
Surface warpage limit 0.05 mm (0.0020 inch)
Surface grinding limit 0.3 mm (0.012 inch)
Standard height 127.5 mm (5.02 inch)
Crankshaft Pulley bolts 180 Nm (18.3 kgf-cm, 132.7 ft. lbs.)
Part 1:
Cylinder Head and Camshaft
Camshaft Bearing
For Cylinder Head bolt sequence, refer to Engine; Service and Repair; Procedures; STI; Disassembly and Reassembly; Cylinder Head Assembly.Cylinder Head Assembly
Cylinder head bolts:
1) Apply a coat of engine oil to washers and bolt threads.
2) Tighten all bolts in sequence to 29 Nm (3.0 kgf-m, 22 ft. lbs.)
3) Retighten all bolts in sequence to 69 Nm (7.0 kgf-m, 51 ft. lbs.)
4) Back off all bolts by 180° first, then back them off a further 180°, in the reverse sequence they were tightened.
5) Tighten all bolts in sequence to 49 Nm (5.0 kgf-m, 36 ft. lbs.)
6) Tighten all bolts in sequence to 80 - 90°
7) Tighten all bolts in sequence a further 40 - 45°
NOTE: Do not tighten bolts for more than 45°.
8) Tighten bolt (A) and (B) a further 40 - 45°.
NOTE: Make sure the sum of retightening angles in previous steps has not exceeded 90°.
Part 5:
Cylinder Head and Valve Assembly
Part 1:
Part 2:
CYLINDER BLOCK
CRANKSHAFT AND PISTON
Crankshaft
Bend limit 0.035 mm (0.0014 inch)
Crank pin and crank journal
Out-of-roundness 0.005 mm (0.0002 inch) or less
Grinding limit 0.25 mm (0.0098 inch)
Crank pin outer diameter
STD 51.984 - 52.000 mm (2.0466 - 2.0472 inch)
0.03 mm (0.0012 inch) US 51.954 - 51.970 mm (2.0454 - 2.0461 inch)
0.05 mm (0.0020 inch) US 51.934 - 51.950 mm (2.0447 - 2.0453 inch)
0.25 mm (0.0098 inch) US 51.734 - 51.750 mm (2.0368 - 2.0374 inch)
Crank journal outer diameter
#1, #3, #5
STD 59.992 - 60.008 mm (2.3619 - 2.3625 inch)
0.03 mm (0.0012 inch) US 59.962 - 59.978 mm (2.3607 - 2.3613 inch)
0.05 mm (0.0020 inch) US 59.942 - 59.958 mm (2.3599 - 2.3605 inch)
0.25 mm (0.0098 inch) US 59.742 - 59.758 mm (2.3520 - 2.3527 inch)
#2, #4
STD 59.992 - 60.008 mm (2.3619 - 2.3625 inch)
0.03 mm (0.0012 inch) US 59.962 - 59.978 mm (2.3607 - 2.3613 inch)
0.05 mm (0.0020 inch) US 59.942 - 59.958 mm (2.3599 - 2.3605 inch)
0.25 mm (0.0098 inch) US 59.742 - 59.758 mm (2.3520 - 2.3527 inch)
Thrust clearance
STD 0.030 - 0.115 mm (0.0012 - 0.0045 inch)
Limit 0.25 mm (0.0098 inch)
Oil clearance
#1
STD 0.003 - 0.030 mm (0.00012 - 0.0012 inch)
Limit 0.040 mm (0.0016 inch)
#2
STD 0.012 - 0.033 mm (0.0004 - 0.0012 inch)
Limit 0.045 mm (0.0018 inch)
#3
STD 0.003 - 0.030 mm (0.00012 - 0.0012 inch)
Limit 0.040 mm (0.0016 inch)
#4
STD 0.012 0.033 mm (0.0004 - 0.0012 inch)
Limit 0.045 mm (0.0018 inch)
#5
STD 0.010 0.031 mm (0.0004 - 0.0012 inch)
Limit 0.040 mm (0.0016 inch)
Piston clearance
STD -0.010 - 0.010 mm (-0.0004 - 0.0004 inch)
Limit 0.030 mm (0.0012 inch)
Enlarging (boring) limit 0.5 mm (0.020 inch)
Piston
Outer diameter
STD
A 99.505 - 99.515 mm (3.9175 - 3.9179 inch)
B 99.495 - 99.505 mm (3.9171 - 3.9175 inch)
0.25 mm (0.0098 inch) OS 99.745 - 99.765 mm (3.9270 - 3.9278 inch)
0.50 mm (0.0197 inch) 99.995 - 100.015 mm (3.9368 - 3.9376 inch
Crankshaft side clearance
Standard 0.030 - 0.115 mm (0.0012 - 0.0045 inch)
Limit 0.25 mm (0.0098 inch)
Part 1:
Part 2:
ENGINE MOUNTING
FRONT EXHAUST PIPE
Water pump and gasket
First 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.)
Second 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.)
Crankshaft Pulley Bolt
Stage 1 44 Nm (4.5 kgf-m, 33 ft. lbs.)
Stage 2 180 Nm (18.3 kgf-m, 132.7 ft. lbs.)
Stage 3 angle 65 degrees or more
Front belt cover bolts:
Belt cover No.2 (LH) 5 Nm (0.5 kgf-cm, 3.6 ft. lbs.)
Camshaft Bearing
Connecting rod cap
Connecting rod
Bend twist per 100 mm (3.94 inch) length
Limit 0.10 mm (0.0039 inch)
Side clearance
STD 0.070 - 0.330 mm (0.0028 - 0.0130 inch)
Limit 0.4 mm (0.016 inch)
Intake Manifold 8.25 Nm (0.84 kgf-m, 6.1 ft-lb)