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Service Data

Service Data Specification Table (1 Of 3)

Compression Pressure at 250 rpm STD 1,226 kPa (12.5 kgf/cm2 , 178 psi) or more
Minimum 981 kPa (10.0 kgf/cm2 ,142 psi)
Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm2 ,14 psi) or less
Valve clearance at cold Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.)
Valve clearance adjusting shim No. 00 2.000 mm (0.0787 in.)
02 2.020 mm (0.0795 in.)
04 2.040 mm (0.0803 in.)
06 2.060 mm (0.0811 in.)
08 2.080 mm (0.0819 in.)
10 2.100 mm (0.0827 in.)
12 2.120 mm (0.0835 in.)
14 2.140 mm (0.0843 in.)
16 2.160 mm (0.0850 in.)
18 2.180 mm (0.0858 in.)
20 2.200 mm (0.0866 in.)
22 2.220 mm (0.0874 in.)
24 2.240 mm (0.0882 in.)
26 2.260 mm (0.0890 in.)
28 2.280 mm (0.0898 in.)
30 2.300 mm (0.0906 in.)
32 2.320 mm (0.0913 in.)
34 2.340 mm (0.0921 in.)
36 2.360 mm (0.0929 in.)
38 2.380 mm (0.0937 in.)
40 2.400 mm (0.0945 in.)
42 2.420 mm (0.0953 in.)
44 2.440 mm (0.0961 in.)
46 2.460 mm (0.0969 in.)
48 2.480 mm (0.0976 in.)
50 2.500 mm (0.0984 in.)
52 2.520 mm (0.0992 in.)
54 2.540 mm (0.1000 in.)
56 2.560 mm (0.1008 in.)
58 2.580 mm (0.1016 in.)
60 2.600 mm (0.1024 in.)
62 2.620 mm (0.1031 in.)
64 2.640 mm (0.1039 in.)
66 2.660 mm (0.1047 in.)
68 2.680 mm (0.1055 in.)
70 2.700 mm (0.1063 in.)
72 2.720 mm (0.1071 in.)
74 2.740 mm (0.1079 in.)
76 2.760 mm (0.1087 in.)
78 2.780 mm (0.1094 in.)
80 2.800 mm (0.1102 in.)
Ignition timing - 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 Specification Table (2 Of 3)

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 bush 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 set bolt thread inside diameter STD 9.770 - 9.960 mm (0.3846 - 0.3921 in.)
Minimum 9.70 mm (0.3819 in.)
Valve guide bush Inside diameter 5.510 - 5.530 mm (0.2169 - 0.2177 in.)
Outside diameter (for repair part) STD 10.333 - 10.344 mm (0.4068 - 0.4072 in.)
O/S 0.05 10.383 - 10.394 mm (0.4088 - 0.4092 in.)
Valve Valve overall length STD Intake 94.80 - 95.30 mm (3.7323 - 3.7520 in.)
Exhaust 94.85 - 95.35 (3.7342 - 3.7539 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 (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
Margin thickness STD 1.0 mm (0.039 in.)
Minimum 0.5 mm (0.020 in.)
Valve compression 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 (20.8 - 23.0 kgf.cm, 45.9 - 50.7 lbf)
Valve lifter Lifter diameter 30.968 - 30.976 mm (1.2192 - 2.2195 in.)
Lifter bore diameter 31.000 - 31.016 mm (1.2205 - 1.2211 in.)
Oil clearance STD 0.024 - 0.048 mm (0.0009 - 0.0018 in.)
Maximum 0.07 mm (0.0028 in.)
Camshaft Thrust clearance STD Intake 0.060 - 0.100 mm (0.0024 - 0.0039 in.)
Exhaust 0.030 - 0.075 mm (0.0012 - 0.0030 in.)
Maximum Intake 0.13 mm (0.0051 in.)
Exhaust 0.12 mm (0.0047 in.)
Journal oil clearance STD 0.030 - 0.067 mm (0.0012 - 0.0026 in.)
Maximum 0.100 mm (0.0039 in.)
Journal diameter for camshaft bearing 26.954 - 26.970 mm (1.0612 - 1.0618 in.)
for camshaft timing tube 30.984 - 31.000 mm (1.2198 - 1.2205 in.)
Circle runout Maximum 0.08 mm (0.0031 in.)
Cam lobe height STD Intake 42.610 - 42.710 mm (1.6776 - 1.6815 in.)
Exhaust 42.630 - 42.730 mm (1.6783 - 1.6823 in.)
Minimum Intake 42.46 mm (1.6717 in.)
Exhaust 42.48 mm (1.6724 in.)
Camshaft gear backlash STD 0.020 - 0.200 mm (0.0008 - 0.0079 in.)
Maximum 0.30 mm (0.0188 in.)
Camshaft timing gear bolt washer 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 STD 0.036 - 0.057 mm (0.0014 - 0.0022 in.)
Maximum 0.075 mm (0.0030 in.)
Cylinder block Cylinder head surface warpage Maximum 0.07 mm (0.0028 in.)
Cylinder bore diameter STD Mark 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.)
Maximum 91.229 mm (3.5917 in.)
Crankshaft bearing cap bolt tension portion diameter STD 7.500 - 7.600 mm (0.2953 - 0.2992 in.)
Minimum 7.20 mm (0.2835 in.)
Service Data Specification Table (3 Of 3)

Piston and piston ring Piston diameter STD Mark 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 STD 0.080 - 0.101 mm (0.0031 - 0.0040 in.)
Maximum 0.121 mm (0.0048 in.)
Piston ring groove clearance No. 1 0.030 - 0.080 mm (0.0012 - 0.0031 in.)
No. 2 0.020 - 0.060 mm (0.0008 - 0.0024 in.)
Piston ring end gap STD No. 1 0.300 - 0.500 mm (0.0118 - 0.0197 in.)
No. 2 0.400 - 0.600 mm (0.0157 - 0.0236 in.)
Oil 0.150 - 0.500 mm (0.0059 - 0.0197 in.)
Maximum No. 1 1.10 mm (0.0433 in.)
No. 2 1.20 mm (0.0472 in.)
Oil 1.10 mm (0.0433 in.)
Connecting rod Thrust clearance STD 0.160 - 0.290 mm (0.0063 - 0.0138 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 0.021 - 0.047 mm (0.0008 - 0.0019 in.)
Maximum 0.065 mm (0.0026 in.)
Connecting rod bearing center wall thickness (Reference)  
Mark 2 1.487 - 1.490 mm (0.0585 - 0.0587 in.)
3 1.490 - 1.493 mm (0.0587 - 0.0588 in.)
4 1.493 - 1.496 mm (0.0588 - 0.0589 in.)
5 1.496 - 1.499 mm (0.0589 - 0.0590 in.)
6 1.499 - 1.502 mm (0.0590 - 0.0591 in.)
7 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.)
Bush 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.)
Bush 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.)
Minimum 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 2.440 - 2.490 mm (0.0961 - 0.0980 in.)
Crankshaft journal bore diameter on cylinder block (with bearing) 66.986 - 67.000 mm (2.6372 - 2.6378 in.)
Crankshaft journal oil clearance STD No. 1 and No. 5 0.017 - 0.033 mm (0.0007 - 0.0013 in.)
Others 0.029-0.045 mm (0.0011 - 0.0018 in.)
Maximum No. 1 and No. 5 0.043 mm (0.0017 in.)
Others 0.055 mm (0.0022 in.)
Crankshaft journal diameter 66.988 - 67.000 mm (2.6373 - 2.6378 in.)
Crankshaft bearing center wall thickness (Reference)  
No. 1 and No. 5 Mark 3 2.492 - 2.495 mm (0.0981 - 0.0982 in.)
4 2.495 - 2.498 mm (0.0982 - 0.0983 in.)
5 2.498 - 2.501 mm (0.0983 - 0.0985 in.)
6 2.501 - 2.504 mm (0.0985 - 0.0986 in.)
7 2.504 - 2.507 mm (0.0986 - 0.0987 in.)
Others Mark 1 2.486 - 2.489 mm (0.0979 - 0.0980 in.)
2 2.489 - 2.492 mm (0.0980 - 0.0981 in.)
3 2.492 - 2.495 mm (0.0981 - 0.0982 in.)
4 2.495 - 2.498 mm (0.0982 - 0.0983 in.)
5 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.)
Crankshaft 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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