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Service Data

ENGINE 

SERVICE DATA

Ignition timing Terminal TC and CG of DLC3 connected 8 to 12°BTDC at idle (Transmission in neutral)
Terminals TC and CG of DLC3 disconnected 5 to 15°BTDC at idle (Transmission in neutral)
Idle speed 600 to 700 RPM (Transmission in neutral)
Compression Compression pressure 1.4 MPa (14 kgf*cm, 199 psi)
Minimum pressure 0.98 MPa (10 kgf*cm2 , 142 psi)
Difference between each cylinder 0.1 MPa (1.0 kgf*cm2 , 15psi) or less

ENGINE UNIT 

TORQUE SPECIFICATIONS

Cylinder head set bolt Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum 10.7 mm (0.421 in.)
Chain Elongation Minimum 136.9 mm (5.390 in.)
No. 2 chain Elongation Minimum 137.6 mm (5.417 in.)
Crank shaft timing gear or sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.417 in.)
Idle sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.417 in.)
Idle gear shaft Idle gear shaft diameter 30.000 to 30.013 mm (1.1811 to 1.1816 in.)
Idle gear inside diameter 30.020 to 30.033 mm (1.1819 to 1.1824 in.)
Oil clearance Standard 0.007 to 0.033 mm (0.0003 to 0.0013in.)
Maximum 0.083 mm (0.0033 in.)
Cylinder head set bolt diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum 10.7 mm (0.4213 in.)
No. 2 chain tensioner assembly Worn depth Maximum 0.9 mm (0.035 in.)
No. 3 chain tensioner assembly Worn depth Maximum 0.9 mm (0.035 in.)
Chain tensioner slipper Worn depth Maximum 1.0 mm (0.039 in.)
No. 1 chain vibration damper Worn depth Maximum 1.0 mm (0.039 in.)
No. 2 chain vibration damper Worn depth Maximum 1.0 mm (0.039 in.)
Cylinder head sub-assembly Cylinder head lower 0.05 mm (0.0020 in.)
Intake 0.08 mm (0.0031 in.)
Exhaust 0.08 mm (0.0031 in.)
Warpage Maximum 0.10 mm (0.0039 in.)
Intake valve Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Margin thickness Standard 1.0 mm (0.039 in.)
Maximum 0.5 mm (00.197 in.)
Overall length Standard 105.65 mm (4.1594 in.)
Maximum 105.15 mm (4.1398 in.)
Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Margin thickness Standard 1.1 mm (0.0433 in.)
Maximum 0.5 mm (00.197 in.)
Overall length Standard 111.50 mm (4.3898 in.)
Maximum 111.00 mm (4.3701 in.)
Inner compression spring Free length 46.51 mm (1.8311 in.)
Deviation Maximum 1.0 mm (0.039 in.)
Angle (reference) Maximum 2°
Intake valve guide bush Inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Maximum 0.08 mm (0.0031 in.)
Bush bore diameter Use STD 10.285 to 10.306 (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height 10.20 to 10.60 mm (0.4016 to 0.4173 in.)
Exhaust valve guide bush Inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum 0.10 mm (0.0039 in.)
Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height 9.30 to 9.70mm (0.3661 to 0.3819 in.)
No. 1 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Cam lobe height Standard 43.950 to 44.050 mm (1.7303 to 1.7342 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
No. 2 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Cam lobe height Standard 44.110 to 44.210 mm (1.7366 to 1.7405 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
No. 3 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
  Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Cam lobe height Standard 43.950 to 44.050 mm (1.7303 to 1.7342 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
No. 4 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.0016 in.)
Cam lobe height Standard 44.110 to 44.210 mm (1.7366 to 1.7405 in.)
Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 (0.0010 to 0.0024 in.)
Maximum No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum 0.15 mm (0.0059 in.)
Ring pin for cylinder head subassembly Protrusion height 2.5 to 3.8 mm (0.098 to 0.150 in.)
Straight pin for cylinder head subassembly Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)
Connecting rod thrust clearance Standard 0.15 to 0.40 (0.0059 to 0.0157 in.)
Maximum 0.50 mm (0.020 in.)
Connecting rod oil clearance Standard 0.045 to 0.067 (0.0018 to 0.0026 in.)
Maximum 0.070 mm (0.0028 in.)
Crankshaft thrust clearance Standard 0.04 to 0.24 (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Cylinder block warpage Maximum 0.07 mm (0.0028 in.)
Cylinder bore diameter Standard 87.500 to 87.512 mm (3.4449 to 3.4453 in.)
Maximum 87.700 mm (3.4527 in.)
Piston diameter Distance 11.1 mm (0.437 in.)
Standard 87.476 to 87.486 mm (3.4439 to 3.4443 in.)
Maximum 87.346 mm 3.4388 in.)
Piston oil clearance Standard 0.014 to 0.036 mm (0.0006 to 0.0014 in.)
Maximum 0.06 mm (0.0023 in.)
Connecting rod out-of alignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod twist Maximum 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
Piston pin hole inside diameter Mark A: 21.998 to 22.001 mm (0.8661 to 0.8662 in.)
Mark B: 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
Mark C: 22.004 to 22.007 mm (0.8663 to 0.8664 in.)
Piston pin diameter Mark A: 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
Mark B: 22.000 to 22.003 mm (0.8661 to 0.8663 in.)
Mark C: 22.003 to 22.006 mm (0.8663 to 0.8664 in.)
Piston oil clearance Standard -0.002 to 0.004 mm (0.00004 to 0.00002 in.)
Maximum 0.015 mm (0.0006 in.)
Connecting rod bushing inside diameter Mark A: 22.005 to 22.008 mm (0.8663 to 0.8665 in.)
Mark B: 22.009 to 22.011 mm (0.8665 to 0.8666 in.)
Mark C: 22.011 to 22.014 mm (0.8666 to 0.8667 in.)
Connecting rod bushing oil clearance Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum 0.03 mm (0.0012 in.)
Piston ring groove clearance No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil 0.020 to 0.065 mm (0.0008 to 0.0026 in.)
Piston ring end gap Standard No. 1 0.23 to 0.33 mm (0.0091 to 0.0130 in.)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum No. 1 0.50 mm (0.0197 in.)
No. 2 0.85 mm (0.0335 in.)
Oil (Side rail) 0.70 mm (0.0276 in.)
Connecting rod bolt diameter Standard 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum 7.0 mm (0.276 in.)
Crank shaft bearing cap set bolt diameter Standard 10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Minimum 10.7 mm (0.4213 in.)
Crankshaft circle runout Maximum 0.06 mm (0.0024 in.)
Main journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crankshaft oil clearance Standard 0.014 to 0.036 mm (0.0005 to 0.0014 in.)
Minimum 0.060 mm (0.0023 in.)
Straight pin for cylinder block subassembly Protrusion height Pin A 6 mm (0.236 in.)
Pin B 23 mm (0.906 in.)
Pin C 11 mm (0.433 in.)
Pin D 9 mm (0.354 in.)
Tight plug for cylinder block Depth 0.2 to 1.2 mm (0.007 to 0.047 in.)
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