Cylinder Block Assembly

Cylinder Block Assembly
Cylinder bore 82.00-82.03 mm (3.2283 - 3.2295 inch)
Out-of-round and taper of cylinder bore Less than 0.01 mm (0.0004 inch)
Clearance with piston (To set limits to new parts); 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
Piston
O.D. (To set limits to new parts); 81.97 - 82.00 mm (3.2271 - 3.2283 inch)

Service oversize ; 0.25, 0.50, 0.75, 1.00 mm (0.010, 0.020, 0.030, 0.039 inch) oversize

PISTON 2.0L:

Piston ring
Side clearance
No. 1
Standard 0.04-0.08 mm (0.0015-0.0031 inch)
Limit 0.1 mm (0.004 inch)

No. 2 0.003 -0.07 mm (0.0012-0.0027 inch)

End gap
No. 1
Standard 0.23-0.38 mm (0.0090-0.0149 inch)
Limit 1 mm (0.039 inch)

No. 2
Standard 0.33-0.48 mm (0.0130-0.0189 inch)
Limit 1 mm (0.039 inch)

Oil ring side rail
Standard 0.20-0.60 mm (0.0078-0.0236 inch)
Limit 1 mm (0.039 inch)

Service oversize 0.25, 0.50, 0.75, 1.00 mm (0.010, 0.020, 0.030, 0.039 inch) oversize

Connecting rod
Bend 0.05 mm (0.0020 inch) or less
Twist 0.1 mm (0.004 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 (0.0157 inch)

Connecting rod bearing
Oil clearance (To set limits to new parts); 0.024-0.044 mm (0.0009-0.0017 inch)
Undersize 0.25, 0.50, 0.75 mm (0.01, 0.20, 0.03 inch)

CRANKSHAFT 2.0L:

Crankshaft
Pin O.D. 45 mm (1.77 inch)
Journal O.D. 57 mm (2.244 inch)
Bend 0.03 mm (0.0012 inch) or less
Out-of-round, taper of journal and pin.......0.01 mm (0.0004 inch) or less
End play

Standard 0.06-0.260 mm (0.0023-0.010 inch)
Limit 0.30 mm (0.0118 inch)

Undersize rework dimension of pin
0.25 mm (0.010 inch) 44.725-44.740 mm (1.7608-1.7614 inch)
0.50 mm (0.020 inch) 44.475-44.490 mm (1.7509-1.7516 inch)
0.75 mm (0.030 inch) 44.225-44.240 mm (1.7411-1.7417 inch)
Undersize rework dimension of journal
0.25 mm (0.010 inch) 56.727-56.742 mm (2.2333-2.2339 inch)
0.50 mm (0.020 inch) 56.417-56.492 mm (2.2235-2.2240 inch)
0.75 mm (0.030 inch) 56.227-56.242 mm (2.2136-2.2142 inch)



TIGHTENING TORQUE
Front engine support bracket bolt and nut 35-50 Nm (350-500 kg-cm, 25-37 ft. lbs.)
Front roll stopper bracket bolt 70-90 Nm (700-900 kg-cm, 51-65 ft. lbs.)
Rear roll stopper bracket bolt 70-90 Nm (700-900 kg-cm, 51-65 ft. lbs.)
Rear engine stopper bracket bolt 35-50 Nm (350-500 kg-cm, 25-37 ft. lbs.)
Connecting rod cap nut 50-53 Nm (500-530 kg-cm, 36-39 ft. lbs.)
Crankshaft bearing cap bolt; 27-33+(60°-65° Nm) (270-330+[60°-65°] kgf-cm, 20-24+[60°-65°] ft. lbs.)
Crankshaft pulley bolt 170-180 Nm (1700-1800 kg.cm, 125-133 ft. lbs.)



* Install bearing caps and tighten the cap bolts to the specified torque in the sequence of the center, No.2, No.4 front and rear caps.
* Cap bolts should be tightened evenly in from 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.

Main bearing cap bolt: ........27 - 33 Nm (270 - 330 kg.cm, 20 - 24 ft. lbs.) + (60° - 65°)
Connecting rod cap bolt: ..........50 - 53 Nm (500 - 530 kg.cm, 37 - 39 ft. lbs.)