Cylinder Block Assembly: Specifications
Cylinder BlockCylinder head surface warpage
Maximum 0.05 mm (0.0020 inch)
Cylinder bore diameter
STD 94.990 to 95.003 mm (3.7398 to 3.7403 inch)
Crankshaft bearing cap bolt outside diameter
STD 10.76 to 10.97 mm (0.4236 to 0.4319 inch)
Minimum 10.66 mm (0.4197 inch)
Piston and piston ring
Piston diameter
STD 94.941 to 94.971 mm (3.7378 to 3.7390 inch)
O/S 0.50 95.441 to 95.471 mm (3.7575 to 3.7587 inch)
Piston oil clearance 0.019 to 0.052 mm (0.0007 to 0.0020 inch)
Piston ring groove clearance
No. 1 0.020 to 0.075 mm (0.0008 to 0.0030 inch)
No. 2 0.020 to 0.065 mm (0.0008 to 0.0026 inch)
Oil 0.020 to 0.070 mm (0.0008 to 0.0028 inch)
Piston ring end gap
STD No. 1 0.22 to 0.034 mm (0.0087 to 0.0134 inch)
No. 2 0.45 to 0.57 mm (0.0177 to 0.0224 inch)
Oil 0.10 to 0.40 mm (0.0039 to 0.0157 inch)
Crankshaft bearing
Lower bearing dimension
No. 1, 5 3.75 mm (0.1476 inch)
No. 3 1.75 mm (0.0689 inch)
No. 2, 4 2.75 mm (0.1083 inch)
Connecting rod
Thrust clearance
STD 0.150 to 0.350 mm (0.0059 to 0.0138 inch)
Maximum 0.4 mm (0.016 inch)
Connecting rod oil clearance
STD 0.024 to 0.049 mm (0.0009 to 0.0019 inch)
Connecting rod bearing center wall thickness (Reference)
Mark 4 1.484 to 1.487 mm (0.0584 to 0.0585 inch)
5 1.488 to 1.490 mm (0.0586 to 0.0587 inch)
6 1.491 to 1.493 mm (0.0587 to 0.0588 inch)
Rod bend
Maximum per 100 mm (3.94 inch) 0.03 mm (0.0012 inch)
Rod twist
Maximum per 100 mm (3.94 inch) 0.15 mm (0.0059 inch)
Bush inside diameter 22.005 to 22.014 mm (0.8663 to 0.8667 inch)
Piston pin diameter
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)
Mark D 22.007 to 22.009 mm (0.8664 to 0.8665 inch)
Bush oil clearance
STD 0.001 to 0.007 mm (0.00004 to 0.00028 in)
Maximum 0.010 mm (0.0039 inch)
Connecting rod bolt tension portion diameter
STD 7.2 to 7.3 mm (0.283 to 0.287 inch)
Maximum 7.0 mm (0.276 inch)
Crankshaft
Thrust clearance
STD 0.020 to 0.220 mm (0.0008 to 0.0087 inch)
Maximum 0.30 mm (0.0118 inch)
Thrust washer thickness 2.440 to 2.490 mm (0.0961 to 0.0980 inch)
Crankshaft journal bore diameter on cylinder block with bearing (Reference)
Mark 1 64.004 to 64.010 mm (2.5198 to 2.5201 inch)
Mark 2 64.011 to 64.016 mm (2.5201 to 2.5203 inch)
Mark 3 64.017 to 64.022 mm (2.5203 to 2.5206 inch)
Crankshaft journal oil clearance
STD No. 3 0.030 to 0.055 mm (0.0012 to 0.0022 inch)
STD Others 0.024 to 0.049 mm (0.0009 to 0.0019 inch)
Maximum 0.10 mm (0.0039 inch)
Crankshaft journal diameter
No. 3 59.981 to 59.994 mm (2.3615 to 2.3620 inch)
Others 59.987 to 60.000 mm (2.3619 to 2.3622 inch)
Crankshaft bearing center wall thickness (Reference)
Mark 1 1.987 to 1.990 mm (0.0782 to 0.0783 inch)
Mark 2 1.990 to 1.993 mm (0.0784 to 0.0785 inch)
Mark 3 1.943 to 1.996 mm (0.0785 to 0.0786 inch)
Crank pin diameter 52.989 to 53.002 mm (2.0862 to 2.0867 inch)
Circle runout
Maximum 0.03 mm (0.0012 inch)
Crankshaft journal taper and out-of-round
Maximum 0.005 mm (0.0002 inch)
Crank pin taper and out-of-round
Maximum 0.003 mm (0.0001 inch)
Engine mounting bracket front No. 1 RH x Cylinder block sub-assembly 51 Nm (520 kgf-cm, 38 ft. lbs.)
Engine coolant temperature sensor x Cylinder block sub-assembly 20 Nm (204 kgf-cm, 15 ft. lbs.)
Engine mounting bracket front No. 1 LH x Cylinder block sub-assembly 51 Nm (520 kgf-cm, 38 ft. lbs.)
Balanceshaft drive gear sub-assembly x Cylinder block sub-assembly 25 Nm (250 kgf-cm, 18 ft. lbs.)
Chain tensioner assembly No. 2 x Cylinder block sub-assembly 18 Nm (185 kgf-cm, 13 ft. lbs.)
Chain vibration damper No. 3 x Cylinder block sub-assembly 18 Nm (185 kgf-cm, 13 ft. lbs.)
Chain vibration damper No. 2 x Cylinder block sub-assembly 27 Nm (270 kgf-cm, 20 ft. lbs.)
Chain vibration damper No. 1 x Cylinder head sub-assembly
Bolt 21 Nm (214 kgf-cm, 15 ft. lbs.)
Chain vibration damper No. 1 x Cylinder block sub-assembly
Nut 21 Nm (214 kgf-cm, 15 ft. lbs.)
Chain tensioner slipper x Cylinder block sub-assembly 21 Nm (214 kgf-cm, 15 ft. lbs.)
Chain tensioner assembly No. 1 x Cylinder head sub-assembly 10 Nm (102 kgf-cm, 7 ft. lbs.)
Oil pan sub-assembly x Cylinder block sub-assembly 26 Nm (265 kgf-cm, 19 ft. lbs.)
Cylinder head sub-assembly x Cylinder block sub-assembly
1st 39 Nm (398 kgf-cm, 29 ft. lbs.)
2nd Turn 90°
3rd Turn 90°
Crankshaft pulley x Crankshaft 260 Nm (2651 kgf-cm, 192 ft. lbs.)
Engine rear oil seal retainer x Cylinder block 13 Nm (133 kgf-cm, 10 ft. lbs.)
Oil filter bracket union x Cylinder block 25 Nm (255 kgf-cm, 18 ft. lbs.)
Oil filter bracket sub-assembly x Cylinder block 25 Nm (255 kgf-cm, 18 ft. lbs.)
Taper screw plug No. 1 x Cylinder block 25 Nm (250 kgf-cm, 18 ft. lbs.)
Cylinder head x Cylinder block
1st 39 Nm (398 kgf-cm, 29 ft. lbs.)
2nd Turn 90°
3rd Turn 90°
Chain vibration damper No. 1 x Cylinder block 21 Nm (214 kgf-cm, 15 ft. lbs.)
Timing chain cover x Cylinder block
Bolt A 46 Nm (469 kgf-cm, 34 ft. lbs.)
Others 21 Nm (214 kgf-cm, 15 ft. lbs.)
Chain vibration damper No. 2 x Cylinder block 27 Nm (270 kgf-cm, 20 ft. lbs.)
Chain vibration damper No. 3 x Cylinder block 18 Nm (185 kgf-cm, 13 ft. lbs.)
Chain vibration damper No. 4 x Cylinder block 18 Nm (185 kgf-cm, 13 ft. lbs.)
Balanceshaft drive gear sub-assembly x Cylinder block 25 Nm (255 kgf-cm, 18 ft. lbs.)
Oil nozzle No. 1 sub-assembly x Cylinder block 7.0 Nm (71 kgf-cm, 62 inch lbs.)
Water drain cock sub-assembly x Cylinder block 25 Nm (250 kgf-cm, 18 ft. lbs.)
Connecting rod cap x Connecting rod
1st 25 Nm (255 kgf-cm, 18 ft. lbs.)
2nd Turn 90°
Balanceshaft thrust washer No. 1 x Cylinder block 18 Nm (184 kgf-cm, 13 ft. lbs.)
Balanceshaft thrust washer No. 2 x Cylinder block 18 Nm (184 kgf-cm, 13 ft. lbs.)
V-ribbed belt tensioner assembly x Cylinder block sub-assembly
Bolt A 21 Nm (214 kgf-cm, 16 ft. lbs.)
Bolt B 40 Nm (408 kgf-cm, 30 ft. lbs.)
Bolt C 43 Nm (434 kgf-cm, 32 ft. lbs.)
Main Bearing Cap
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 10 main bearing cap bolts in the sequence shown in the illustration.
Torque 39 Nm (398 kgf-cm, 29 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
Crankshaft Pulley
Crankshaft pulley x Crankshaft 260 Nm (2651 kgf-cm, 192 ft. lbs.)