System Specifications

HEAD SET BOLT






CYLINDER BORE
Standard diameter 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter 94.132mm (3.7060 in.)

SURFACE VARIATION









MAIN BEARING CAP

- Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.





- Install the 2 upper thrust washers onto the No. 2 journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil grooves facing outward.





- Install the 2 lower thrust washers onto the No. 2 bearing cap with the grooves facing outward.





- Examine the front marks and numbers, check the sequence number is as shown in the illustration and install the bearing caps on the cylinder block.
- Apply a light coat of engine oil to the threads of bearing cap bolts.
- Temporarily install the 8 main bearing cap bolts in the inside positions.





- Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 in.).





- Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
- Apply a light coat of engine oil to the threads of main bearing cap bolts.





- Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft-lbf)





- Mark the front side of the bearing cap bolts with paint.
- Retighten the bearing cap bolts 90° in the sequence as shown.
- Check that the painted mark is now at a 90° angle from the front.
- Check that the crankshaft turns smoothly.





- Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)





There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5"
accordingly.

Journal bearing:





EXAMPLE
Cylinder block "11" (A) + Crankshaft "06" (B) =Total number 17 (Use bearing "3")





CRANKSHAFT
















CRANKSHAFT TIMING GEAR OR SPROCKET

Minimum gear diameter (with chain) 61.0 mm (2.402 in.)

PISTON SUB-ASSEMBLY WITH CONNECTING ROD





- Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
- Check the position of the piston ring ends.
- Using a piston ring compressor, push the correct number piston and connecting rod into each cylinder with the front mark of the piston facing forward.

NOTICE:
- Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oils and fats.
- Match the numbered connecting rod cap with the connecting rod.





- Check that the protrusion of the connecting rod cap is facing in the correct direction.
- Apply a light coat of engine oil to the threads of the connecting rod cap bolts.





- Using SST, tighten the bolts alternately to the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)





- Mark the front side of the each connecting cap bolt with paint.
- Retighten the cap bolts 90° as shown.
- Check that the crankshaft turns smoothly.


CONNECTING ROD





PISTON





PISTON RING





CRANKSHAFT PULLEY

Torque 250 Nm (2,549 kgf-cm, 185 ft-lbf)