Service Data
ENGINE MECHANICAL SERVICE DATA SPECIFICATION
| Ignition timing | Terminals TC and CG of DLC3 connected | 10 +- 2° BTDC idle (Transmission in neutral) |
|---|---|---|
| Terminals TC and CG of DLC3 disconnected | 7 to 24° BTDC idle (Transmission in neutral) | |
| Idle speed | 700 +- 50 rpm (Transmission in neutral) | |
| Compression | Compression pressure | 1.3 MPa (13.3 kgf/cm2 , 189 psi) or more |
| Minimum pressure | 1.0 MPa (10.2 kgf/cm2 ,145 psi) | |
| Difference between each cylinder | 0.1 MPa (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 gear No. 1 | ||
| Diameter (with chain) | 61.0 mm (2.402 in.) | |
| Cylinder head set bolt | ||
| Outside diameter | Standard | 10.85 to 11.00 mm (0.4272 to 0.4331 in.) |
| Minimum | 10.7 mm (0.421 in.) | |
| Chain | ||
| Elongation | Maximum | 146.8 mm (5.780 in.) |
| No. 2 chain | ||
| Elongation | Maximum | 146.8 mm (5.780 in.) |
| Idle gear shaft | ||
| Idle gear shaft diameter | 22.987 to 23.000 mm (0.9050 to 0.9055 in.) | |
| Idle gear inside 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 | ||
| Worn depth | Maximum | 1.0 mm (0.039 in.) |
| Chain tensioner assembly No. 3 | ||
| Worn depth | Maximum | 1.0 mm (0.039 in.) |
| Chain tensioner slipper | ||
| Worn depth | Maximum | 1.0 mm (0.039 in.) |
| Chain vibration damper No. 1 | ||
| Worn depth | Maximum | 1.0 mm (0.039 in.) |
| Chain vibration damper No. 2 | ||
| Worn depth | 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 | 44.5° | |
| 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 | 106.40 mm (4.1890 in.) | |
| Exhaust valve | ||
| Valve stem diameter | 5.465 to 5.480 mm (0.2152 to 0.2158 in.) | |
| Valve face angle | 44.5° | |
| Margin thickness | Standard | 1.0 mm (0.039 in.) |
| Minimum | 0.5 mm (0.020 in.) | |
| Overall length | Standard | 105.80 mm (4.1653 in.) |
| Minimum | 105.30 mm (4.1457 in.) | |
| Inner compression spring | ||
| Deviation | Maximum | 2.0 mm (0.079 in.) |
| Free length | 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.) | |
| Bush 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.) | |
| Bush 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.) | |
| Lifter 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.) | |
| Circuit 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 | Standard No. 1 journal | 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 No. 1 journal | 0.07 mm (0.0028 in.) | |
| Other journals | 0.10 mm (0.0039 in.) | |
| Thrust clearance | Standard | 0.04 to 0.09 mm (0.0016 to 0.0035 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.) | |
| Circuit 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 | Standard No. 1 journal | 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 (0.0016 to 0.0035 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.) | |
| Circuit 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 | Standard No. 1 journal | 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 (0.0016 to 0.0035 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.) | |
| Circuit 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 | Standard No. 1 journal | 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 (0.0016 to 0.0035 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.) | |
| Connecting rod 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 93.920 mm (3.6972 to 3.6976 in.) | |
| Oil clearance | Standard | 0.080 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 inside diameter | 22.005 to 22.014 mm (0.8663 to 0.8667 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 ring end gap Standard | No. 1 | 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.) | |
| Maximum No. 1 | 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.) | |
| 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.) | |