Cylinder Block Assembly: Specifications

Install the 8 main bearing cap bolts to the outside positions.
Bolt length 105.5 to 107.5 mm (4.15 to 4.23 inch)

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 16 main bearing cap bolts in the sequence shown in the illustration.
Torque 61 Nm (622 kgf-cm, 45 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specification, replace it.

Step 2
Mark the front of the bearing cap bolts with paint.
Tighten the bearing cap bolts another 90° in the order above.

ROD BEARING CAP
The connecting cap bolts are tightened in 2 progressive steps.

Step 1
Install and alternately tighten the bolts of the connecting rod cap in several steps.
SST 09011-38121
Torque 25 Nm (255 kgf-cm, 18 ft. lbs.)

Step 2
Mark the front side of each connecting cap bolt with paint.
Tighten the cap bolts another 90° as shown in the illustration.

Connecting rod diameter

CRANKSHAFT PULLEY 250 Nm (2,550 kgf-cm, 184 ft. lbs.)

CRANKSHAFT CLEARANCE
Standard thrust clearance 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance 0.30 mm (0.0118 inch)
Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 inch)

CYLINDER BORE
Standard diameter 94.000 to 94.012 mm (3.7008 to 3.7013 inch)
Maximum diameter 94.200 mm (3.7087 inch)
If the diameter is greater than the maximum, replace the cylinder block.

CONNECTING ROD CLEARANCE
Standard thrust clearance 0.15 to 0.40 mm (0.0059 to 0.0157 inch)
Maximum thrust clearance 0.50 mm (0.020 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

Ring groove clearance

PISTON RING END GAP
Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.

Standard end nap

Maximum end gap

Piston pin diameter

Bushing inside diameter

CRANKSHAFT
Maximum circle runout 0.06 mm (0.0024 inch)
If the circle runout is greater than the maximum, replace the crankshaft.

Journal bearings

Main Journals
Standard journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 inch)
Maximum taper and out-of-round 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

Crank Pin
Diameter 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
Maximum taper and out-of-round 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

Standard bearing center wall thickness
Crankshaft pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 inch)

CRANKSHAFT BEARING CAP
Standard diameter 10.8 to 11.0 mm (0.4252 to 0.4331 inch)
Minimum diameter 10.7 mm (0.4213 inch)

CYLINDER BLOCK WARPAGE

Maximum warpage 0.07 mm (0.0028 inch)

PISTON SUB-ASSEMBLY WITH PIN
Distance 9.8 mm (0.3858 inch)
Standard diameter 93.960 to 93.980 mm (3.6992 to 3.7000 inch)
Maximum diameter 93.830 mm (3.6941 inch)

Rod Bearing Cap Bolts
1st 25 Nm (255 kgf cm, 18 ft. lbs.)
2nd turn 90°

CONNECTING ROD THRUST CLEARANCE
Standard thrust clearance 0.15 to 0.40 mm (0.0059 to 0.0157 inch)
Maximum thrust clearance 0.50 mm (0.020 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

CONNECTING ROD OIL CLEARANCE
Standard oil clearance 0.045 to 0.067 mm (0.0018 to 0.0026 inch)
Maximum oil clearance 0.070 mm (0.0028 inch)

Connecting rod diameter

Standard bearing center wall thickness
Crankshaft pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 inch)

INSPECT CYLINDER BORE
Standard diameter 94.000 to 94.012 mm (3.7008 to 3.7013 inch)
Maximum diameter 94.200 mm (3.7087 inch)

INSPECT CONNECTING ROD
Maximum out-of alignment 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If out-of-alignment is greater than the maximum, replace the connecting rod assembly.

Maximum twist 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If twist is greater than the maximum, replace the connecting rod assembly.

INSPECT CONNECTING ROD BOLT
Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum diameter 7.0 mm (0.276 inch)
If the diameter is less than the minimum, replace the bolt.

Main bearings come in widths of 18.0 mm (0.709 inch) and 21.0 mm (0.827 inch). Install the 21.0 mm (0.827 inch) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 inch) bearings in the No.2 and No.3 positions.