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Service Data

ENGINE MECHANICAL - SERVICE DATA

Ignition timing Terminals TC and CG of DLC3 connected 8 to 12° BTDC @ idle (Transmission in neutral position).
Terminals TC and CG of DLC3 disconnected 7 to 24° BTDC @ idle (Transmission in neutral position)
Idle speed 650 to 750 rpm (Transmission in neutral position)
Compression Compression pressure 1, 300 kPa (13.3 kgf/cm2 , 189 psi) or more
Minimum pressure 1, 000 kPa (10.2 kgf/cm2 , 145 psi)
Difference between each cylinder 100 kPa (1.0 kgf/cm2 , 15 psi) or less
Valve clearance Intake (cold) 0.15 to 0.25 mm (0.006 to 0.010 in.)
Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)
Intake manifold Intake air surge tank side warpage Maximum 0.8 mm (0.031 in.)
Cylinder head side warpage 0.2 mm (0.008 in.)
Exhaust manifold Warpage Maximum 0.7 mm (0.028 in.)
Camshaft timing gear assembly Diameter (with chain) Large gear 115.5 mm (4.547 in.)
Small gear 73.1 mm (2.878 in.)
Camshaft timing gear or sprocket Diameter (with chain) 73.1 mm (2.878 in.)
Crankshaft timing gear or sprocket Diameter (with chain) 61.0 mm (2.402 in.)
Idle sprocket Diameter (with chain) 61.0 mm (2.402 in.)
Cylinder head set bolt Outer diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum 10.7 mm (0.421 in.)
Chain sub-assembly Length Maximum 146.8 mm (5.780 in.)
No. 2 chain sub-assembly Length Maximum 146.8 mm (5.780 in.)
Idle gear shaft Diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.)
Internal diameter 23.02 to 23.03 mm (0.9063 to 0.9067 in.)
Oil clearance Standard 0.020 to 0.043 mm (0.0008 to 0.0017 in.)
Maximum 0.093 mm (0.0037 in.)
Chain tensioner assembly No. 2 Wear Maximum 1.0 mm (0.039 in.)
Chain tensioner assembly No. 3 Wear Maximum 1.0 mm (0.039 in.)
Chain tensioner slipper Wear Maximum 1.0 mm (0.039 in.)
Chain vibration damper No. 1 Wear Maximum 1.0 mm (0.039 in.)
Chain vibration damper No. 2 Wear Maximum 1.0 mm (0.039 in.)
Cylinder head sub-assembly 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.)
Valve face angle 45.5°
Margin thickness Standard 1.0 mm (0.039 in.)
Minimum 0.5 mm (0.020 in.)
Overall length Standard 106.95 mm (4.2106 in.)
Minimum 106.70 mm (4.2008 in.)
Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Valve face angle 45.5°
Margin thickness Standard 1.0 mm (0.039 in.)
Minimum 0.5 mm (0.020 in.)
Overall length Standard 105.80 mm (41654 in.)
Minimum 105.55 mm (4.1555 in.)
Inner compression spring Deviation Maximum 2.0 mm (0.079 in.)
Free length Maximum 47.80 mm (1.8819 in.)
Tension at 33.3 mm (1.311 in.) 186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf)
Intake valve guide bush Inside diameter 5.51 to 5.53 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.)
Bore diameter 10.295 to 10.315 mm (0.4053 to 0.4061 in.)
Protrusion height 9.3 to 9.7 mm (0.366 to 0.382 in.)
Exhaust valve guide bush Inside diameter 5.51 to 5.53 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.)
Bore diameter 10.295 to 10.315 mm (0.4053 to 0.4061 in.)
Protrusion height 9.3 to 9.7 mm (0.366 to 0.382 in.)
Valve lifter Diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.)
Oil clearance Standard 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum 0.08 mm (0.0031 in.)
No. 1 camshaft Journal diameter No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circle runout Maximum 0.06 mm (0.0024 in.)
Cam lobe height Standard 44.168 to 44.268 mm (1.7389 to 1.7428 in.)
Minimum 44.018 mm (1.7330 in.)
Oil clearance No. 1 journal Standard 0.008 to 0.038 mm (0.0003 to 0.0015 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
No. 1 journal Maximum 0.07 mm (0.0028 in.)
Other journals 0.10 mm (0.0039 in.)
Thrust clearance Standard 0.04 to 0.09 mm (0.016 to 0.035 in.)
Maximum 0.11 mm (0.0043 in.)
No. 2 camshaft Journal diameter No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circle runout Maximum 0.06 mm (0.0024 in.)
Cam lobe height Standard 44.580 to 44.680 mm (1.7551 to 1.7591 in.)
Minimum 44.430 mm (1.7492 in.)
Oil clearance No. 1 journal Standard 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance Standard 0.04 to 0.09 mm (0.016 to 0.035 in.)
Maximum 0.11 mm (0.0043 in.)
No. 3 camshaft sub-assembly Journal diameter No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circle runout Maximum 0.06 mm (0.0024 in.)
Cam lobe height Standard 44.168 to 44.268 mm (1.7389 to 1.7428 in.)
Minimum 44.018 mm (1.7330 in.)
Oil clearance No. 1 journal Standard 0.008 to 0.038 mm (0.0003 to 0.0015 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance Standard 0.04 to 0.09 mm (0.016 to 0.035 in.)
Maximum 0.11 mm (0.0043 in.)
No. 4 camshaft sub-assembly Journal diameter No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circle runout Maximum 0.06 mm (0.0024 in.)
Cam lobe height Standard 44.580 to 44.680 mm (1.7551 to 1.7591 in.)
Minimum 44.430 mm (1.7492 in.)
Oil clearance No. 1 journal Standard 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance Standard 0.04 to 0.09 mm (0.016 to 0.035 in.)
Maximum 0.11 mm (0.0043 in.)
Ring pin for cylinder head sub-assembly and cylinder head LH Protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.)
Straight pin for cylinder head sub-assembly and cylinder head LH Protrusion height A 17.5 to 19.5 mm (0.689 to 0.768 in.)
B 7.5 to 8.5 mm (0.295 to 0.335 in.)
C 7.0 to 9.0 mm (0.276 to 0.354 in.)
Tight plug for cylinder head sub-assembly and cylinder head LH Depth 1.5 mm (0.059 in.)
Connecting rod Thrust clearance Standard 0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum 0.35 mm (0.0138 in.)
Oil clearance Standard 0.026 to 0.046 mm (0.0010 to 0.0018 in.)
Maximum 0.066 mm (0.0025 in.)
Crankshaft thrust clearance Standard 0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Cylinder block warpage Maximum 0.05 mm (0.0020 in.)
Cylinder bore diameter Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum 94.132 mm (3.7060 in.)
Piston Diameter 93.910 to 93.940 mm (3.6972 to 3.6984 in.)
Oil clearance Standard 0.060 to 0.102 mm (0.0031 to 0.0040 in.)
Maximum 0.13 mm (0.0051 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.)
Connecting rod bushing Internal diameter 22.005 to 22.014 mm (0.8662 to 0.8665 in.)
Piston pin Diameter 21.997 to 22.006 mm (0.8660 to 0.8664 in.)
Oil clearance Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum 0.050 mm (0.0020 in.)
Piston ring Groove clearance No. 1 0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil 0.07 to 0.15 mm (0.0028 to 0.0060 in.)
Piston pin Internal diameter 22.001 to 22.010 mm (0.8662 to 0.8665 in.)
Piston ring End gap No. 1 Standard 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2 0.40 to 0.50 mm (0.0157 to 0.0197 in.)
Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
No. 1 Maximum 1.0 mm (0.039 in.)
No. 2 1.1 mm (0.043 in.)
Oil (Side rail) 1.0 mm (0.039 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.)
Thrust clearance Standard 0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Minimum 0.35 mm (0.0138 in.)
Crankshaft bearing cap set bolt Diameter Standard 10.0 to 10.2 mm (0.393 to 0.402 in.)
Crankshaft Circle runout Maximum 0.06 mm (0.0024 in.)
Main journal Diameter 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
Main journal Taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crank pin Diameter 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
Crank pin Taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Crankshaft Oil clearance Standard 0.018 to 0.030 mm (0.0007 to 0.0012 in.)
Maximum 0.046 mm (0.0018 in.)
Thrust clearance - 0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0018 in.)
Straight pin Protrusion Pin A Standard 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C 8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D 5.5 to 6.5 mm (0.217 to 0.256 in.)
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