System Specifications

Displacement 2,488 cm3 (151.82 cu in)
Bore and stroke 89.0 x 100.0 mm (3.504 x 3.937 in)
Surface distortion Limit 0.1 mm (0.004 in)

Cylinder bore Inner diameter
Standard
Grade No. 2 89.010 - 89.020 mm (3.5043 - 3.5047 in)
Grade No. 3 89.020 - 89.030 mm (3.5047 - 3.5051 in)
Wear limit 0.2 mm (0.008 in)

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


Main bearing housing inner diameter grade
Grade No. A 58.944 - 58.945 mm (2.3206 - 2.3207 in)
Grade No. B 58.945 - 58.946 mm (2.3207 - 2.3207 in)
Grade No. C 58.946 - 58.947 mm (2.3207 - 2.3207 in)
Grade No. D 58.947 - 58.948 mm (2.3207 - 2.3208 in)
Grade No. E 58.948 - 58.949 mm (2.3208 - 2.3208 in)
Grade No. F 58.949 - 58.950 mm (2.3208 - 2.3209 in)
Grade No. G 58.950 - 58.951 mm (2.3209 - 2.3209 in)
Grade No. H 58.951 - 58.952 mm (2.3209 - 2.3209 in)
Grade No. J 58.952 - 58.953 mm (2.3209 - 2.3210 in)
Grade No. K 58.953 - 58.954 mm (2.3210 - 2.3210 in)
Grade No. L 58.954 - 58.955 mm (2.3210 - 2.3211 in)
Grade No. M 58.955 - 58.956 mm (2.3211 - 2.3211 in)
Grade No. N 58.956 - 58.957 mm (2.3211 - 2.3211 in)
Grade No. P 58.957 - 58.958 mm (2.3211 - 2.3212 in)
Grade No. R 58.958 - 58.959 mm (2.3212 - 2.3212 in)
Grade No. S 58.959 - 58.960 mm (2.3212 - 2.3213 in)
Grade No. T 58.960 - 58.961 mm (2.3213 - 2.3213 in)
Grade No. U 58.961 - 58.962 mm (2.3213 - 2.3213 in)
Grade No. V 58.962 - 58.963 mm (2.3213 - 2.3214 in)
Grade No. W 58.963 - 58.964 mm (2.3214 - 2.3214 in)
Grade No. X 58.964 - 58.965 mm (2.3214 - 2.3215 in)
Grade No. Y 58.965 - 58.966 mm (2.3215 - 2.3215 in)
Grade No. 4 58.966 - 58.967 mm (2.3215 - 2.3215 in)
Grade No. 7 58.967 - 58.968 mm (2.3215 - 2.3216 in)

Piston skirt diameter"A"
Standard
Grade No. 2 88.990 - 89.000 mm (3.5035 - 3.5039 in)
Grade No. 3 89.000 - 89.010 mm (3.5039 - 3.5043 in)

Piston height "H" dimension 42.98 mm (1.692 in)

Piston pin hole diameter
Grade No. 0 19.993 - 19.999 mm (0.7871 - 0.7874) in
Grade No. 1 19.999 - 20.005 mm (0.7874 - 0.7876) 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 in)
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 (rail ring)
Standard 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit --

End gap
Top
Standard 0.21- 0.31 mm (0.0083 - 0.0122 in)
Limit 0.54 mm (0.0213 in)
2nd
Standard 0.32 - 0.47 mm (0.0126 - 0.0185 in)
Limit 0.65 mm (0.0256 in)

Oil ring (railring)
Standard 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Limit 0.95 mm (0.0374 in)

Piston Pin
Piston pin outer diameter
Grade No. 0 19.989 - 19.995 mm (0.7870 -0.7872 in)
Grade No. 1 19.995 - 20.001 mm (0.7872 -0.7874 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)

Connecting Rod
Center distance 143.00 - 143.10 mm (5.630 - 5.634 in)
Bend [per 100 (3.94)] Limit 0.15 mm (0.0059 in)
Torsion [per 100 (3.94)] Limit 0.30 mm (0.0118 in)
Connecting rod bushing inner diameter*
Grade No. 0 20.000 - 20.006 mm (0.7874 - 0.7876 in)
Grade No. 1 20.006 - 20.012 mm (0.7876 - 0.7879 in)
*: After installing in connecting rod
Side clearance
Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit 0.50 mm (0.0197 in)

Connecting rod big end diameter
Grade No. 0 48.000 - 48.001 mm (1.8898 - 1.8898 in)
Grade No. 1 48.001 - 48.002 mm (1.8898 - 1.8898 in)
Grade No. 2 48.002 - 48.003 mm (1.8898 - 1.8899 in)
Grade No. 3 48.003 - 48.004 mm (1.8899 - 1.8899 in)
Grade No. 4 48.004 - 48.005 mm (1.8899 - 1.8900 in)
Grade No. 5 48.005 - 48.006 mm (1.8900 - 1.8900 in)
Grade No. 6 48.006 - 48.007 mm (1.8900 - 1.8900 in)
Grade No. 7 48.007 - 48.008 mm (1.8900 - 1.8901 in)
Grade No. 8 48.008 - 48.009 mm (1.8901 - 1.8901 in)
Grade No. 9 48.009 - 48.010 mm (1.8901 - 1.8902 in)
Grade No. A 48.010 - 48.011 mm (1.8902 - 1.8902 in)
Grade No. B 48.011 - 48.012 mm (1.8902 - 1.8902 in)
Grade No. C 48.012 - 48.013 mm (1.8902 - 1.8903 in)

Crankshaft
Center distance "r" 49.96 - 50.04 mm (1.9669 - 1.9701 in)
Out-of-round (Difference between "X"and "Y") Limit 0.0025 mm (0.0001 in)
Taper (Difference between "A" and "B") Limit 0.0025 mm (0.0001 in)
Runout [TIR*] Limit 0.05 mm (0.0020 in)
*: Total indicator reading
Crankshaft end play
Standard 0.10 - 0.26 mm (0.0039 - 0.0102 in)
Limit 0.30 mm (0.0118 in)

Pin journal diameter grade. "DP"
Grade No. A 44.974 - 44.973 mm (1.7706 - 1.7706 in)
Grade No. B 44.973 - 44.972 mm (1.7706 - 1.7705 in)
Grade No. C 44.972 - 44.971 mm (1.7705 - 1.7705 in)
Grade No. D 44.971 - 44.970 mm (1.7705 - 1.7705 in)
Grade No. E 44.970 - 44.969 mm (1.7705 - 1.7704 in)
Grade No. F 44.969 - 44.968 mm (1.7704 - 1.7704 in)
Grade No. G 44.968 - 44.967 mm (1.7704 - 1.7704 in)
Grade No. H 44.967 - 44.966 mm (1.7704 - 1.7703 in)
Grade No. J 44.966 - 44.965 mm (1.7703 - 1.7703 in)
Grade No. K 44.965 - 44.964 mm (1.7703 - 1.7702 in)
Grade No. L 44.964 - 44.963 mm (1.7702 - 1.7702 in)
Grade No. M 44.963 - 44.962 mm (1.7702 - 1.7702 in)
Grade No. N 44.962 - 44.961 mm (1.7702 - 1.7701 in)
Grade No. P 44.961 - 44.960 mm (1.7701 - 1.7701 in)
Grade No. R 44.960 - 44.959 mm (1.7701 - 1.7700 in)
Grade No. S 44.959 - 44.958 mm (1.7700 - 1.7700 in)
Grade No. T 44.958 - 44.957 mm (1.7700 - 1.7700 in)
Grade No. U 44.957 - 44.956 mm (1.7700 - 1.7699 in)

Main journal diameter grade. "Dm"
Grade No. A 54.979 - 54.978 mm (2.1645 - 2.1645 in)
Grade No. B 54.978 - 54.977 mm (2.1645 - 2.1644 in)
Grade No. C 54.977 - 54.976 mm (2.1644 - 2.1644 in)
Grade No. D 54.976 - 54.975 mm (2.1644 - 2.1644 in)
Grade No. E 54.975 - 54.974 mm (2.1644 - 2.1643 in)
Grade No. F 54.974 - 54.973 mm (2.1643 - 2.1643 in)
Grade No. G 54.973 - 54.972 mm (2.1643 - 2.1642 in)
Grade No. H 54.972 - 54.971 mm (2.1642 - 2.1642 in)
Grade No. J 54.971 - 54.970 mm (2.1642 - 2.1642 in)
Grade No. K 54.970 - 54.969 mm (2.1642 - 2.1641 in)
Grade No. L 54.969 - 54.968 mm (2.1641 - 2.1641 in)
Grade No. M 54.968 - 54.967 mm (2.1641 - 2.1641 in)
Grade No. N 54.967 - 54.966 mm (2.1641 - 2.1640 in)
Grade No. P 54.966 - 54.965 mm (2.1640 - 2.1640 in)
Grade No. R 54.965 - 54.964 mm (2.1640 - 2.1639 in)
Grade No. S 54.964 - 54.963 mm (2.1639 - 2.1639 in)
Grade No. T 54.963 - 54.962 mm (2.1639 - 2.1639 in)
Grade No. U 54.962 - 54.961 mm (2.1639 - 2.1638 in)
Grade No. V 54.961 - 54.960 mm (2.1638 - 2.1638 in)
Grade No. W 54.960 - 54.959 mm (2.1638 - 2.1637 in)
Grade No. X 54.959 - 54.958 mm (2.1637 - 2.1637 in)
Grade No. Y 54.958 - 54.957 mm (2.1637 - 2.1637 in)
Grade No. 4 54.957 - 54.956 mm (2.1637 - 2.1636 in)
Grade No. 7 54.956 - 54.955 mm (2.1636 - 2.1636 in)

Main Bearing
Undersize
US 0.25 (0.0098)
Thickness 2.106 - 2.114 mm (0.0829 - 0.0832 in)
Main Journal Diameter Grind so that bearing clearance is the specified value

Bearing Oil Clearance
Main bearing oil clearance
Standard No. 1, 3 and 5 0.028 - 0.042 mm (0.0011 - 0.0017 in)
No. 2 and 4 0.041 - 0.056 mm (0.0016 - 0.0022 in)
Limit 0.1 mm (0.004 in)

Connecting Rod Bearing
Grade number
0
Thickness 1.493 - 1.496 mm (0.0588 - 0.0589 in)
Identification color Black
1
Thickness 1.496 - 1.499 mm (0.0589 - 0.0590 in)
Identification color Brown
2
Thickness 1.499 - 1.502 mm (0.0590 - 0.0591 in)
Identification Green
3
Thickness 1.502 - 1.505 mm (0.0591 - 0.0593 in)
Identification Color Yellow
4
Thickness 1.505 - 1.508 mm (00.593 - 0.0594 in)
Identification color Blue

Undersize
US 0.25 (0.0098)
Thickness 1.624 - 1.632 mm (0.0639 - 0.0643 in)
Crank pin journal diameter Grind so that bearing clearance is the specified value.

Connecting Rod Bearing
Connecting rod bearing oil clearance
Standard 0.035 - 0.045 mm (0.0014 - 0.0018 in)
Limit 0.10 mm (0.0039 in)

Crankshaft pulley bolt 42.1 Nm (4.3 kg-m, 31 ft-lb)





Lower cylinder block bolts
Step 1 (bolts 11 -22): 25.1 Nm (2.6 kg-m, 19 ft-lb)
Step 2 (bolts 1 - 10): 39.2 Nm (4.0 kg-m, 29 ft-lb)
Step 3 (bolts 1 - 10): 60 degrees - 65 degrees (target: 60 degrees)

Connecting Rod Bolt
Step 1: 27.4 Nm (2.8 kg-m, 20 ft-lb)
Step 2: 0 Nm (0 kg-m, 0 ft-lb)
Step 3: 19.6 Nm (2.0 kg-m, 14 ft-lb)
Step 4: 85 degrees - 95 degrees (target 90 degrees)