System Specifications

Displacement 3,954 cm3 (241.30 cu in)
Bore and stroke 95.5 � 92.0 mm (3.76 � 3.622 in)

Surface flatness
Standard Less than 0.03 mm (0.0012 in)
Limit 0.1 mm (0.004 in)

Cylinder bore Inner diameter Standard
Grade No. 1 95.500 - 95.510 mm (3.7598 - 3.7602 in)
Grade No. 2 95.510 - 95.520 mm (3.7602 - 3.7606 in)
Grade No. 3 95.520 - 95.530 mm (3.7606 - 3.7610 in)

Out-of-round [Difference between (X) and (Y)]
Limit 0.015 mm (0.0006 in)
Taper [Difference between (A) and (C)] 0.01 mm (0.0004 in)

Main bearing housing inner diameter (Without bearing)
Grade No. A 74.993 - 74.994 mm (2.9525 - 2.9525 in)
Grade No. B 74.994 - 74.995 mm (2.9525 - 2.9526 in)
Grade No. C 74.995 - 74.996 mm (2.9526 - 2.9526 in)
Grade No. D 74.996 - 74.997 mm (2.9526 - 2.9526 in)
Grade No. E 74.997 - 74.998 mm (2.9526 - 2.9527 in)
Grade No. F 74.998 - 74.999 mm (2.9527 - 2.9527 in)
Grade No. G 74.999 - 75.000 mm (2.9527 - 2.9528 in)
Grade No. H 75.000 - 75.001 mm (2.9528 - 2.9528 in)
Grade No. J 75.001 - 75.002 mm (2.9528 - 2.9528 in)
Grade No. K 75.002 - 75.003 mm (2.9528 - 2.9529 in)
Grade No. L 75.003 - 75.004 mm (2.9529 - 2.9529 in)
Grade No. M 75.004 - 75.005 mm (2.9529 - 2.9529 in)
Grade No. N 75.005 - 75.006 mm (2.9529 - 2.9530 in)
Grade No. P 75.006 - 75.007 mm (2.9530 - 2.9530 in)
Grade No. R 75.007 - 75.008 mm (2.9530 - 2.9531 in)
Grade No. S 75.008 - 75.009 mm (2.9530 - 2.9531 in)
Grade No. T 75.009 - 75.010 mm (2.9531 - 2.9531 in)
Grade No. U 75.010 - 75.011 mm (2.9531 - 2.9532 in)
Grade No. V 75.011 - 75.012 mm (2.9532 - 2.9532 in)
Grade No. W 75.012 - 75.013 mm (2.9532 - 2.9533 in)
Grade No. X 75.013 - 75.014 mm (2.9533 - 2.9533 in)
Grade No. Y 75.014 - 75.015 mm (2.9533 - 2.9533 in)
Grade No. 4 75.015 - 75.016 mm (2.9533 - 2.9534 in)
Grade No. 7 75.016 - 75.017 mm (2.9534 - 2.9534 in)

Difference in inner diameter between cylinders Standard Less than 0.03 mm (0.0012 in)

Piston
Piston skirt diameter (A)
Grade No.1 95.480 - 95.490 mm (3.7590 -3.7594 in)
Grade No.2 95.490 - 95.500 mm (3.7594 -3.7598 in)
Grade No.3 95.500 - 95.510 (3.7598 -3.7602 in)

(a) dimension 43.03 mm (1.6941 in)

Piston pin hole diameter
Grade No.
Standard 0 21.993 - 21.999 mm (0.8659 -0.8661 in)
Grade No. 1
Standard 21.999 - 22.005 mm (0.8661 -0.8663 in)

Piston to cylinder bore clearance
Standard 0.010 - 0.030 mm (0.0004 -0.0012 in)
Limit 0.08 mm (0.0031 in)

Piston Ring
Side clearance
Top
Standard 0.045 - 0.080 mm (0.0018 -0.0031)
Limit 0.11 mm (0.0043 in)

2nd
Standard 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Limit 0.10 mm (0.0039 in)

Oil ring
Standard 0.065 - 0.135 mm (0.0026 -0.0053 in)

End gap
Top 0.23 - 0.33 mm (0.0091 - 0.0130) 0.56 (0.0220 in)
2nd 0.33 - 0.48 mm (0.0130 - 0.0189) 0.68 (0.0268 in)
Oil (rail ring) 0.20 - 0.50 mm (0.0079 - 0.0197) 0.85 (0.0335 in)

Piston Pin
Piston pin outer diameter
Grade No. 0 21.989 - 21.995 mm (0.8657 -0.8659 in)
Grade No. 1 21.995 - 22.001 mm (0.8659 -0.8662 in)

Piston to piston pin oil clearance
Standard 0.002 - 0.006 mm (0.0001 -0.0002 in)

Connecting rod bushing oil clearance
Standard 0.005 - 0.017 mm (0.0002 -0.0007 in)
Limit 0.030 mm (0.0012 in)

Connecting Rod
Center distance
Standard 165.82 - 165.92 mm (6.5283 - 6.5323 in)
Bend [per 100 (3.94)]
Standard -
Limit 0.15 mm (0.0059 in)
Torsion [per 100 (3.94)]
Standard -
Limit 0.30 mm (0.0118 in)

Connecting rod bushing inner diameter*
Grade No. 0
Standard 22.000 - 22.006 mm (0.8661 -0.8664 in)
Grade No. 1
Standard 22.006 - 22.012 mm (0.8664 -0.8666 in)
*: After installing in connecting rod

Connecting rod big end diameter (Without bearing)
Standard 57.000 - 57.013 mm (2.2441 - 2.2446 in)

Side clearance
Standard 0.20 - 0.35 mm (0.0079 -0.0138 in)
Limit 40 mm (0.0157 in)

Crankshaft
Main journal diameter. (Dm) grade Standard
Grade No. A 69.975 - 69.974 mm (2.7549 - 2.7549 in)
Grade No. B 69.974 - 69.973 mm (2.7549 - 2.7548 in)
Grade No. C 69.973 - 69.972 mm (2.7548 - 2.7548 in)
Grade No. D 69.972 - 69.971 mm (2.7548 - 2.7548 in)
Grade No. E 69.971 - 69.970 mm (2.7548 - 2.7547 in)
Grade No. F 69.970 - 69.969 mm (2.7547 - 2.7547 in)
Grade No. G 69.969 - 69.968 mm (2.7547 - 2.7546 in)
Grade No. H 69.968 - 69.967 mm (2.7546 - 2.7546 in)
Grade No. J 69.967 - 69.966 mm(2.7546 - 2.7546 in)
Grade No. K 69.966 - 69.965 mm (2.7546 - 2.7545 in)
Grade No. L 69.965 - 69.964 mm (2.7545 - 2.7545 in)
Grade No. M 69.964 - 69.963 mm (2.7545 - 2.7544 in)
Grade No. N 69.963 - 69.962 mm (2.7544 - 2.7544 in)
Grade No. P 69.962 - 69.961 mm (2.7544 - 2.7544 in)
Grade No. R 69.961 - 69.960 mm (2.7544 - 2.7543 in)
Grade No. S 69.960 - 69.959 mm (2.7543 - 2.7543 in)
Grade No. T 69.959 - 69.958 mm (2.7543 - 2.7542 in)
Grade No. U 69.958 - 69.957 mm (2.7542 - 2.7542 in)
Grade No. V 69.957 - 69.956 mm (2.7542 - 2.7542 in)
Grade No. W 69.956 - 69.955 mm (2.7542 - 2.7541 in)
Grade No. X 69.955 - 69.954 mm (2.7541 - 2.7541 in)
Grade No. Y 69.954 - 69.953 mm (2.7541 - 2.7540 in)
Grade No. 4 69.953 - 69.952 mm (2.7540 - 2.7540 in)
Grade No. 7 69.952 - 69.951 mm (2.7540 - 2.7540 in)

Pin journal diameter. (Dp) grade
Standard
Grade No. 0 53.968 - 53.974 mm (2.1247 - 2.1250 in)
Grade No. 1 53.962 - 53.968 mm (2.1245 - 2.1247 in)
Grade No. 2 53.956 - 53.962 mm (2.1242 - 2.1245 in)

Center distance (r) 45.96 - 46.04 mm (1.8094 - 1.8126 in)
Taper [Difference between (A) and (B)] Limit 0.002 mm (0.0001 in)
Out-of-round [Difference between (X) and (Y)] 0.002 mm (0.0001 in)
Crankshaft runout [TIR*]
Standard Less than 0.05 mm (0.002 in)
Limit 0.10 mm (0.0039 in)
*: Total indicator reading

Crankshaft end play
Standard 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit 0.30 mm (0.0118 in)

Main Bearing
Under Size
0.25 mm (0.0098)
Thickness 2.633 - 2.641 mm (0.1037 - 0.1040 in)
Main journal diameter Grind so that bearing clearance is the specified value.

Main bearing oil clearance
Standard 0.035 - 0.045 mm (0.0014 - 0.0018 in)
Limit * 0.065 mm (0.0026 in)
*: Actual Clearance

Connecting Rod Bearing
Grade number 0
Thickness 0 1.500 - 1.503 mm (0.0591 - 0.0592 in)
Identification color (mark) Black

Grade number 1
Thickness 1.503 - 1.506 mm (0.0592 - 0.0593) in
Identification color (mark) Brown

Grade number 2
Thickness 1.506 - 1.509 mm (0.0593 - 0.0594) in
Identification color (mark) Green

Connecting Rod Bearing
Undersize
0.25 (0.0098)
Thickness 1.626 - 1.634 mm (0.0640 - 0.0643 in)
Crank pin journal diameter Grind so that bearing clearance is the specified value.

Connecting Rod Bearing Oil Clearance
Connecting rod bearing oil clearance
Standard 0.034 - 0.059 mm (0.0013 - 0.0023 in)*
Limit 0.070 mm (0.0028 in)
*: Actual Clearance

Tighten lower cylinder block as follows:
Tighten M8 bolts in numerical order as shown from No. 17 to 24.





Bolts 17- 24 :22.1 Nm (2.3 kg-m, 16 ft-lb)

Step 1: Tighten M10 bolts in numerical order.





Bolts 1 - 16: 35.3 Nm (3.6 kg-m, 26 ft-lb)
Step 2: Turn M10 bolts 90° clockwise in numerical order.

Connecting rod bolt: 19.6 Nm (2.0 kg-m, 14 ft-lb)
Then tighten all connecting rod bolts 90° clockwise.

Tighten crankshaft pulley bolt in two steps.
Step 1 : 44.1 Nm (4.5 kg-m, 33 ft-lb)
Step 2 : 84 - 90 degrees clockwise