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Service Data

SERVICE DATA CHART

Compression pressure at 250 rpm STD
Minimum
Difference of pressure between each cylinder		 1,226 kPa (12.5 kgf/cm2 ,178 psi) or more
981 kPa (10.0 kgf/cm2 , 142 psi)
98 kPa (1.0 kgf/cm2 , 14 psi) or less
Valve clearance Valve clearance adjusting shim :
  1. at cold Intake
  2. Exhaust
  3. No.00
  4. No.02
  5. No.04
  6. No.06
  7. No.08
  8. No.10
  9. No.12
  10. No.14
  11. No.16
  12. No.18
  13. No.20
  14. No.22
  15. No.24
  16. No.26
  17. No.28
  18. No.30
  19. No.32
  20. No.34
  21. No.36
  22. No.38
  23. No.40
  24. No.42
  25. No.44
  26. No.46
  27. No.48
  28. No.50
  29. No.52
  30. No.54
  31. No.56
  32. No.58
  33. No.60
  34. No.62
  35. No.64
  36. No.66
  37. No.68
  38. No.70
  39. No.72
  40. No.74
  41. No.76
  42. No.78
  43. No.80
  1. 0.15 - 0.25 mm (0.006 - 0.010 in.)
  2. 0.25 - 0.35 mm (0.010 - 0.014 in.)
  3. 2.000 mm (0.0787 in.)
  4. 2.020 mm (0.0795 in.)
  5. 2.040 mm (0.0803 in.)
  6. 2.060 mm (0.0811 in.)
  7. 2.080 mm (0.0819 in.)
  8. 2.100 mm (0.0827 in.)
  9. 2.120 mm (0.0835 in.)
  10. 2.140 mm (0.0843 in.)
  11. 2.160 mm (0.0850 in.)
  12. 2.180 mm (0.0858 in.)
  13. 2.200 mm (0.0866 in.)
  14. 2.220 mm (0.0874 in.)
  15. 2.240 mm (0.0882 in.)
  16. 2.260 mm (0.0890 in.)
  17. 2.280 mm (0.0898 in.)
  18. 2.300 mm (0.0906 in.)
  19. 2.320 mm (0.0913 in.)
  20. 2.340 mm (0.0921 in.)
  21. 2.360 mm (0.0929 in.)
  22. 2.380 mm (0.0937 in.)
  23. 2.400 mm (0.0945 in.)
  24. 2.420 mm (0.0953 in.)
  25. 2.440 mm (0.0961 in.)
  26. 2.460 mm (0.0969 in.)
  27. 2.480 mm (0.0976 in.)
  28. 2.500 mm (0.0984 in.)
  29. 2.520 mm (0.0992 in.)
  30. 2.540 mm (0.1000 in)
  31. 2.560 mm (0.1008 in.)
  32. 2.580 mm (0.1016 in.)
  33. 2.600 mm (0.1024 in.)
  34. 2.620 mm (0.1031 in.)
  35. 2.640 mm (0.1039 in.)
  36. 2.660 mm (0.1047 in.)
  37. 2.680 mm (0.1055 in.)
  38. 2.700 mm (0.1063 in.)
  39. 2.720 mm (0.1071 in.)
  40. 2.740 mm (0.1079 in.)
  41. 2.760 mm (0.1087 in.)
  42. 2.780 mm (0.1094 in.)
  43. 2.800 mm (0.1102 in.)
Ignition timing w/ Terminals TC and CG connected of DLC3 8-12° BTDC @ idle
Idle speed - 750 +/- 50 rpm
Timing belt tensioner Protrusion from housing end 9.5 - 10.5 mm (0.374 - 0.413 in.)
SERVICE DATA CHART

Cylinder head Warpage :
  1. Maximum
  1. 0.10 mm (0.039 in.)
Valve seat
  1. Refacing angle
  2. Contacting angle
  3. Contacting width
  1. 30°, 45°, 60°
  2. 45°
  3. 1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide bushing bore diameter :
  1. STD
  2. O/S 0.05
  1. 10.285 - 10.306 mm (0.4049 - 0.4057 in.)
  2. 10.335 - 10.356 mm (0.4069 - 0.4077 in.)
Cylinder head bolt thread inside diameter :
  1. STD
  2. Minimum
  1. 9.770 - 9.960 mm (0.3846 - 0.3921 in.)
  2. 9.70 mm (0.3819 in.)
Valve guide bushing Inside diameter 5.510 - 5.530 mm (0.2169 - 0.2177 in.)
Outside diameter (for repair part) :
  1. STD
  2. O/S 0.05
  1. 10.333 - 10.344 mm (0.4068 - 0.4072 in.)
  2. 10.383 - 10.394 mm (0.4088 - 0.4092 in.)
Valve Valve overall length :
  1. STD Intake
  2. Exhaust
  3. Minimum Intake
  4. Exhaust
  1. 94.80 - 95.30 mm (3.7323 - 3.7520 in.)
  2. 94.85 - 95.35 (3.7342 - 3.7539 in.)
  3. 94.55 mm (3.7224 in.)
  4. 94.60 mm (3.7244 in.)
Valve face angle 44.5°
Stem diameter :
  1. Intake
  2. Exhaust
  1. 5.470 - 5.485 mm (0.2154 - 0.2159 in.)
  2. 5.465 - 5.480 mm (0.2152 - 0.2157 in.)
Stem oil clearance :
  1. STD Intake
  2. Exhaust
  3. Maximum Intake
  4. Exhaust
  1. 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
  2. 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
  3. 0.08 mm (0.0031 in.)
  4. 0.10 mm (0.0039 in.)
Margin thickness :
  1. STD
  2. Minimum
  1. 1.0 mm (0.039 in.)
  2. 0.5 mm (0.020 in.)
Valve spring Deviation : Maximum 2.0 mm (0.079 in.)
Free length 54.05 - 54.15 mm (2.1279 - 2.1319 in.)
Installed tension : at 35.04 mm (1.3795 in.) 210 - 226 N (21.4 - 23.0 kgf.cm, 47.2 - 50.7 lbf)
Valve lifter Lifter diameter 30.968 - 30.978 mm (1.2192 - 1.2196 in.)
Lifter bore diameter 31.000 - 31.016 mm (1.2205 - 1.2211 in.)
Oil clearance :
  1. STD
  2. Maximum
  1. 0.024 - 0.048 mm (0.0009 - 0.0018 in.)
  2. 0.07 mm (0.0028 in.)
Camshaft Thrust clearance :
  1. STD Intake
  2. Exhaust
  3. Maximum Intake
  4. Exhaust
  1. 0.060 - 0.100 mm (0.0024 - 0.0039 in.)
  2. 0.030 - 0.075 mm (0.0012 - 0.0030 in.)
  3. 0.13 mm (0.0051 in.)
  4. 0.12 mm (0.0047 in.)
Journal oil clearance :
  1. STD
  2. Maximum
  1. 0.030 - 0.067 mm (0.0012 - 0.0026 in.)
  2. 0.100 mm (0.0039 in.)
Journal diameter :
  1. for camshaft bearing
  2. for camshaft timing tube
  1. 26.954 - 26.970 mm (1.0612 - 1.0618 in.)
  2. 30.984 - 31.000 mm (1.2198 - 1.2205 in.)
Circle runout 0.08 mm (0.0031 in.)
Cam lobe height :
  1. STD Intake
  2. Exhaust
  3. Minimum Intake
  4. Exhaust
  1. 42.610 - 42.710 mm (1.6776 - 1.6815 in.)
  2. 42.630 - 42.730 mm (1.6783 - 1.6823 in.)
  3. 42.46 mm (1.6717 in.)
  4. 42.48 mm (1.6724 in.)
Camshaft gear backlash :
  1. STD
  2. Maximum
  1. 0.020 - 0.200 mm (0.0008 - 0.0079 in.)
  2. 0.30 mm (0.0188 in.)
Camshaft gear spring end free distance 18.2 - 18.8 mm (0.712 - 0.740 in.)
Camshaft timing tube Journal diameter 39.955 - 39.964 mm (1.5730 - 1.5734 in.)
Journal oil clearance :
  1. STD
  2. Maximum
  1. 0.036 - 0.057 mm (0.0014 - 0.0022 in.)
  2. 0.075 mm (0.0030 in.)
Manifold Warpage :
  1. Maximum Intake
  2. Exhaust
  1. 0.15 mm (0.0059 in.)
  2. 0.50 mm (0.0197 in.)
Cylinder block Cylinder head surface warpage : Maximum 0.07 mm (0.0028 in.)
Cylinder bore diameter :
  1. STD Mark 1
  2. Mark 2
  3. Mark 3
  4. Maximum
  1. 91.000 - 91.008 mm (3.5827 - 3.5830 in.)
  2. 91.008 - 91.021 mm (3.5830 - 3.5835 in.)
  3. 91.021 - 91.029 mm (3.5835 - 3.5838 in.)
  4. 91.229 mm (3.5917 in.)
Main bearing cap bolt tension portion diameter :
  1. STD
  2. Minimum
  1. 7.500 - 7.600 mm (0.2953 - 0.2992 in.)
  2. 7.20 mm (0.2835 in.)
Piston and piston ring Piston diameter :
  1. STD Mark 1
  2. Mark 2
  3. Mark 3
  1. 90.910 - 90.920 mm (3.5791 - 3.5795 in.)
  2. 90.920 - 90.928 mm (3.5795 - 3.5798 in.)
  3. 90.928 - 90.938 mm (3.5798 - 3.5802 in.)
Piston oil clearance :
  1. STD
  2. Maximum
  1. 0.080 - 0.101 mm (0.0031 - 0.0040 in.)
  2. 0.121 mm (0.0048 in.)
Piston ring groove clearance :
  1. No.1
  2. No.2
  1. 0.030 - 0.080 mm (0.0012 - 0.0031 in.)
  2. 0.020 - 0.060 mm (0.0008 - 0.0024 in.)
Piston ring end gap :
  1. STD No.1
  2. No.2
  3. Oil
  4. Maximum No.1
  5. No.2
  6. Oil
  1. 0.300 - 0.500 mm (0.0118 - 0.0197 in.)
  2. 0.400 - 0.600 mm (0.0157 - 0.0236 in.)
  3. 0.150 - 0.500 mm (0.0059 - 0.0197 in.)
  4. 1.10 mm (0.0433 in.)
  5. 1.20 mm (0.0472 in.)
  6. 1.10 mm (0.0433 in.)
Connecting rod Thrust clearance :
  1. STD
  2. Maximum
  1. 0.160 - 0.290 mm (0.0063 - 0.0138 in.)
  2. 0.35 mm (0.0138 in.)
Connecting rod thickness 22.880 - 22.920 mm (0.9008 - 0.9024 in.)
Connecting rod oil clearance :
  1. STD
  2. Maximum
  1. 0.021 - 0.047 mm (0.0008 - 0.0019 in.)
  2. 0.065 mm (0.0026 in.)
Connecting rod bearing center wall thickness (Reference) :
  1. Mark 2
  2. Mark 3
  3. Mark 4
  4. Mark 5
  5. Mark 6
  6. Mark 7
  1. 1.487 - 1.490 mm (0.0585 - 0.0587 in.)
  2. 1.490 - 1.493 mm (0.0587 - 0.0588 in.)
  3. 1.493 - 1.496 mm (0.0588 - 0.0589 in.)
  4. 1.496 - 1.499 mm (0.0589 - 0.0590 in.)
  5. 1.499 - 1.502 mm (0.0590 - 0.0591 in.)
  6. 1.502 - 1.505 mm (0.0591 - 0.0593 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 :
  1. STD
  2. Maximum
  1. 0.005 - 0.011 mm (0.0002 - 0.0004 in)
  2. 0.05 mm (0.0020 in.)
Connecting rod bolt tension portion diameter :
  1. STD
  2. Minimum
  1. 7.200 - 7.300 mm (0.2835 - 0.2874 in.)
  2. 7.00 mm (0.2756 in.)
Crankshaft Thrust clearance :
  1. STD
  2. Maximum
  1. 0.020 - 0.220 mm (0.0008 - 0.0087 in.)
  2. 0.30 mm (0.0118 in.)
Thrust washer thickness 2.440 - 2.490 mm (0.0961 - 0.0980 in.)
Main journal bore diameter on cylinder block (with main bearing) 66.986 - 67.000 mm (2.6372 - 2.6378 in.)
Main journal oil clearance :
  1. STD No.1 and No.5
  2. Others
  3. Maximum No.1 and No 5
  4. Others
  1. 0.017 - 0.033 mm (0.0007 - 0.0013 in.)
  2. 0.029 - 0.045 mm (0.0011 - 0.0018 in.)
  3. 0.043 mm (0.0017 in.)
  4. 0.055 mm (0.0022 in.)
Main journal diameter 66.988 - 67.000 mm (2.6373 - 2.6378 in.)
Main bearing center wall thickness (Reference) :
  1. No.1 and No.5 Mark 3
  2. Mark 4
  3. Mark 5
  4. Mark 6
  5. Mark 7

    6. Others 

  6. Mark 1
  7. Mark 2
  8. Mark 3
  9. Mark 4
  10. Mark 5
  1. 2.492 - 2.495 mm (0.0981 - 0.0982 in.)
  2. 2.495 - 2.498 mm (0.0982 - 0.0983 in.)
  3. 2.498 - 2.501 mm (0.0983 - 0.0985 in.)
  4. 2.501 - 2.504 mm (0.0985 - 0.0986 in.)
  5. 2.504 - 2.507 mm (0.0986 - 0.0987 in.)
  6. 2.486 - 2.489 mm (0.0979 - 0.0980 in.)
  7. 2.489 - 2.492 mm (0.0980 - 0.0981 in.)
  8. 2.492 - 2.495 mm (0.0981 - 0.0982 in.)
  9. 2.495 - 2.498 mm (0.0982 - 0.0983 in.)
  10. 2.498 - 2.501 mm (0.0983 - 0.0985 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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