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Service Data

MECHANICAL SERVICE DATA

Ignition timing Terminals TC and CG of DLC3 connected 8 - 12° BTDC @ idle (Transmission in neutral position)
Idle speed 650 - 750 r/min
Compression Compression pressure 1226 kPa (12.5 kgf/cm2 , 178 psi) or more
Minimum pressure 981 kPa (10 kgf/cm2 , 142 psi)
Difference between each cylinder 98 kPa (1.0 kgf/cm2 , 14 psi)
valve clearence
Intake (cold) 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust (cold) 0.25 - 0.35 mm (0.010 - 0.014 in.)
Cylinder head
Warpage Maximum 0.10 mm (0.039 in.)
Valve seat
  Refacing angle 30°, 45°, 60°
  Contacting angle 45°
  Contacting width 1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide bushing bore diameter STD 10.285 - 10.306 mm (0.4049 - 0.4057 in.)
O/S 0.05 10.335 - 10.356 mm (0.4069 - 0.4077 in.)
Cylinder head seat bolt thread inside diameter STD 9.810 - 9.960 mm (0.3862 - 0.3921 in.)
Minimum 9.70 mm (0.3819 in.)
Protrusion height Intake 9.2 - 9.8 mm (0.362 - 0.386 in.)
Exhaust 8.2 - 8.8 mm (0.323 - 0.346 in.)
Valve guide bushing
Inside diameter 5.510 - 5.530 mm (0.2169 - 0.2177 in.)
Outside diameter (for repair part) STD 10.285 - 10.306 mm (0.4049 - 0.4057 in.)
O/S 0.05 10.335 - 10.356 mm (0.4069 - 0.4077 in.)
Valve Valve overall length STD Intake 95.05 mm (3.7421 in.)
Exhaust 95.10 mm (3.7441 in.)
Minimum Intake 94.55 mm (3.7224 in.)
Exhaust 94.60 mm (3.7244 in.)
Valve face angle 44.5°
Stem diameter Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.)
Exhaust 5.465 - 5.480 mm (0.2152 - 0.2157 in.)
Stem oil clearance STD Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum Intake 0.08 mm (0.031 in.)
Exhaust 0.10 mm (0.039 in.)
Margin thickness STD IN 1.25 mm (0.049 in.)
EX 1.4 mm (0.055 in.)
Minimum 0.5 mm (0.020 in.)
Valve spring Deviation Maximum 2.0 mm (0.079 in.)
Free length 54.1 mm (2.130 in.)
Installed tension at 35.0 mm (1.378 in.) 210 - 226 N (21.4 - 23.0 kgf.cm, 47.2 - 50.7 lbf)
Lifter diameter Lifter diameter 30.968 - 30.976 mm (1.2192 - 1.2195 in.)
Lifter bore diameter 31.000 - 31.016 mm (1.2205 - 1.2211 in.)
Oil clearance STD 0.024 - 0.050 mm (0.0009 - 0.0020 in.)
Maximum 0.07 mm (0.0028 in.)
Camshaft Thrust clearance STD Intake 0.040 - 0.090 mm (0.0016 - 0.0035 in.)
Exhaust 0.030 - 0.075 mm (0.0012 - 0.0030 in.)
Minimum Intake 0.12 mm (0.0047 in.)
Exhaust 0.10 mm (0.0039 in.)
Journal oil diameter STD 0.030 - 0.071 mm (0.012 - 0.0028 in.)
Maximum 0.10 mm (0.039 in.)
Journal diameter 26.954 - 26.970 mm (1.0612 - 1.0618 in.)
Circuit runout Maximum 0.08 mm (0.031 in.)
Cam lobe height STD Intake 41.94 - 42.04 mm (1.6512 - 1.6551 in.)
Exhaust 41.96 - 42.06 mm (1.6520 - 1.6559 in.)
Minimum Intake 41.79 mm (1.6453 in.)
Exhaust 41.81 mm (1.6461 in.)
Camshaft gear backlash STD 0.020 - 0.200 mm (0.0008 - 0.0079 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft gear bolt washer end free distance 18.2 - 18.8 mm (0.712 - 0.740 in.)
Cylinder block Cylinder head surface warpage Maximum 0.07 mm (0.0028 in.)
Cylinder bore diameter STD Mark 1 94.002 - 94.010 mm (3.7009 - 3.7012 in.)
Mark 2 94.010 - 94.023 mm (3.7012 - 3.7017 in.)
Mark 3 94.023 - 94.031 mm (3.7017 - 3.7020 in.)
Maximum STD 94.231 mm (3.7099 in.)
O/S 0.5 94.731 mm (3.7296 in.)
Main bearing cap bolt tension portion diameter STD 10.760 - 10.970 mm (0.4236 - 0.4319 in.)
Minimum 10.40 mm (0.4094 in.)
Piston and piston ring Piston diameter STD Mark 1 93.902 - 93.912 mm (3.6969 - 3.6973 in.)
Mark 2 93.912 - 93.920 mm (3.6973 - 3.6976 in.)
Mark 3 93.920 - 93.930 mm (3.6976 - 3.6980 in.)
O/S 0.5 94.402 - 94.430 mm (3.7168 - 3.7177 in.)
Piston oil clearance STD 0.090 - 0.111 mm (0.0035 - 0.0044 in.)
Maximum 0.13 mm (0.0051 in.)
Piston ring groove clearance No. 1 0.030 - 0.080 mm (0.0012 - 0.0032 in.)
No. 2 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
Piston ring end gap No. 1 0.300 - 0.400 mm (0.0118 - 0.0158 in.)
No. 2 0.130 - 0.380 mm (0.0051 - 0.0150 in.)
Oil 0.130 - 0.380 mm (0.0051 - 0.0150 in.)
Maximum No. 1 1.10 mm (0.0433 in.)
No. 2 1.20 mm (0.0472 in.)
Oil 1.15 mm (0.0453 in.)
Connecting rod Thrust clearance STD 0.160 - 0.290 mm (0.0063 - 0.0114 in.)
Maximum 0.35 mm (0.0138 in.)
Connecting rod thickness 22.880 - 22.920 mm (0.9008 - 0.9024 in.)
Connecting rod oil clearance STD 0.027 - 0.053 mm (0.0011 - 0.0021 in.)
Maximum 0.065 mm (0.0026 in.)
Connecting rod bearing center wall thickness Mark 2 1.484 - 1.487 mm (0.0584 - 0.0585 in.)
Mark 3 1.487 - 1.490 mm (0.0585 - 0.0587 in.)
Mark 4 1.490 - 1.493 mm (0.0587 - 0.0588 in.)
Mark 5 1.493 - 1.496 mm (0.0588 - 0.0589 in.)
Mark 6 1,496 - 1.499 mm (0.0589 - 0.0590 in.)
Mark 7 1.499 - 1.502 mm (0.0590 - 0.0591 in.)
Rod bend Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
Bushing inside diameter 22.005 - 22.014 mm (0.8663 - 0.8667 in.)
Piston pin diameter 21.997 - 22.006 mm (0.8660 - 0.8664 in.)
Bushing oil clearance STD 0.005 - 0.011 mm (0.0002 - 0.0004 in.)
Maximum 0.05 mm (0.0020 in.)
Connecting rod bolt tension portion diameter STD 7.200 - 7.300 mm (0.2835 - 0.2874 in.)
Maximum 7.00 mm (0.2756 in.)
Crankshaft Thrust clearance STD 0.020 - 0.220 mm (0.0008 - 0.0087 in.)
Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness STD 2.440 - 2.490 mm (0.0961 - 0.0980 in.)
U/S 0.125 2.503 - 2.553 mm (0.0985 - 0.1005 in.)
Main journal bore diameter on cylinder block 72.000 - 72.016 mm (2.8347 - 2.8353 in.)
Main journal oil clearance No. 1 and No. 5 STD 0.028 - 0.046 mm (0.0011 - 0.0018 in.)
Others STD 0.040 - 0.058 mm (0.0016 - 0.0023 in.)
No. 1 and No. 5 Maximum 0.065 mm (0.0026 in.)
Others Maximum 0.065 mm (0.0026 in.)
Main journal diameter 66.988 - 67.000 mm (2.6373 - 2.6378 in.)
Main bearing center wall thickness No. 1 and No. 5 Mark 3 2.487 - 2.490 mm (0.0979 - 0.0980 in.)
Mark 4 2.490 - 2.493 mm (0.0980 - 0.0982 in.)
Mark5 2493 - 2.496 mm (0.0982 - 0.0983 in.)
Mark 6 2.496 - 2.499 mm (0.0983 - 0.0984 in.)
Mark 7 2.499 - 2.502 mm (0.0984 - 0.0985 in.)
Other Mark 1 2.481 - 2.484 mm (0.0977 - 0.0978 in.)
Mark 2 2.484 - 2.487 mm (0.0978 - 0.0979 in.)
Mark 3 2.487 - 2.490 mm (0.0979 - 0.0980 in.)
Mark 4 2.490 - 2.493 mm (0.0980 - 0.0982 in.)
Marks 5 2.493 - 2.496 mm (0.0981 - 0.0983 in.)
Crank pin diameter 51.982 - 52.000 mm (2.0465 - 2.0472 in.)
Circle runout Maximum 0.08 mm (0.0031 in.)
Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.)
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