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 | 8 to 18°BTDC at idle (Transmission in neutral) | |
| Idle speed | 950 to 1,050 rpm (Transmission in neutral) | |
| Compression | Compression pressure | 1.0 MPa (10 kgf*cm, 143 psi) |
| Minimum pressure | 0.7 MPa (7.1 kgf*cm 2 , 101 psi) | |
| Difference between each cylinder | 0.1 MPa (1.0 kgf*cm 2 , 15 psi) or less | |
ENGINE
| Intake manifold | Standard maximum warpage (Intake manifold side) | 0.1 mm (0.003 in.) |
|---|---|---|
| Standard maximum warpage (Cylinder head side) | 0.1 mm (0.003 in.) | |
| Intake air surge tank | Standard maximum warpage | 2.5 mm (0.098 in.) |
| Exhaust manifold | Maximum warpage | 0.7 mm (0.028 in.) |
ENGINE ASSEMBLY
| Connecting rod big end inside diameter | Mark 1 | 56.000 to 56.006 mm (2.2047 to 2.2050 in.) | |
|---|---|---|---|
| Mark 2 | 56.007 to 56.012 mm (2.2050 to 2.2052 in.) | ||
| Mark 3 | 56.013 to 56.018 mm (2.2052 to 2.2054 in.) | ||
| Mark 4 | 56.019 to 56.024 mm (2.2055 to 2.2057 in.) | ||
| Standard sized bearing center wall thickness | Mark 1 | 1.481 to 1.484 mm (0.0583 to 0.0584 in.) | |
| Mark 2 | 1.484 to 1.487 mm (0.0584 to 0.0585 in.) | ||
| Mark 3 | 1.487 to 1.490 mm (0.0585 to 0.0587 in.) | ||
| Mark 4 | 1.490 to 1.493 mm (0.0587 to 0.0588 in.) | ||
| Standard crankshaft main journal diameter | Mark 00 | 60.999 to 61.000 mm (2.4015 to 2.4016 in.) | |
| Mark 01 | 60.998 to 60.999 mm (2.4015 to 2.4015 in.) | ||
| Mark 02 | 60.997 to 60.998 mm (2.4015 to 2.4015 in.) | ||
| Mark 03 | 60.996 to 60.997 mm (2.4014 to 2.4015 in.) | ||
| Mark 04 | 60.995 to 60.996 mm (2.4014 to 2.4014 in.) | ||
| Mark 05 | 60.994 to 60.995 mm (2.4013 to 2.4014 in.) | ||
| Mark 06 | 60.993 to 60.994 mm (2.4013 to 2.4013 in.) | ||
| Mark 07 | 60.992 to 60.993 mm (2.4013 to 2.4013 in.) | ||
| Mark 08 | 60.991 to 60.992 mm (2.4012 to 2.4013 in.) | ||
| Mark 09 | 60.990 to 60.991 mm (2.4012 to 2.4012 in.) | ||
| Mark 10 | 60.989 to 60.990 mm (2.4011 to 2.4012 in.) | ||
| Mark 11 | 60.988 to 60.989 mm (2.4011 to 2.4011 in.) | ||
| Standard upper bearing center wall thickness No. 1 and No. 4 journal | Mark 1 | 2.500 to 2.503 mm (0.0984 to 0.0985 in.) | |
| Mark 2 | 2.503 to 2.506 mm (0.0985 to 0.0987 in.) | ||
| Mark 3 | 2.506 to 2.509 mm (0.0987 to 0.0988 in.) | ||
| Mark 4 | 2.509 to 2.512 mm (0.0988 to 0.0989 in.) | ||
| Mark 5 | 2.512 to 2.515 mm (0.0989 to 0.0990 in.) | ||
| No. 2 and No. 3 journal | Mark 1 | 2.475 to 2.478 mm (0.0974 to 0.0976 in.) | |
| Mark 2 | 2.478 to 2.481 mm (0.0976 to 0.0977 in.) | ||
| Mark 3 | 2.481 to 2.484 mm (0.0977 to 0.0978 in.) | ||
| Mark 4 | 2.484 to 2.487 mm (0.0978 to 0.0979 in.) | ||
| Mark 5 | 2.487 to 2.490 mm (0.0979 to 0.0980 in.) | ||
| Standard lower bearing center wall thickness No. 1 and No. 4 journal | Mark 1 | 2.478 to 2.481 mm (0.0976 to 0.0977 in.) | |
| Mark 2 | 2.481 to 2.484 mm (0.0977 to 0.0978 in.) | ||
| Mark 3 | 2.484 to 2.487 mm (0.0978 to 0.0979 in.) | ||
| Mark 4 | 2.487 to 2.490 mm (0.0979 to 0.0980 in.) | ||
| Mark 5 | 2.490 to 2.493 mm (0.0980 to 0.0981 in.) | ||
| No. 2 and No. 3 journal | Mark 1 | 2.497 to 2.500 mm (0.0983 to 0.0984 in.) | |
| Mark 2 | 2.500 to 2.503 mm (0.0984 to 0.0985 in.) | ||
| Mark 3 | 2.503 to 2.506 mm (0.0985 to 0.0987 in.) | ||
| Mark 4 | 2.506 to 2.509 mm (0.0987 to 0.0988 in.) | ||
| Mark 5 | 2.509 to 2.512 mm (0.0988 to 0.0989 in.) | ||
| Cylinder head set bolt | Standard | 10.85 to 11.00 mm (0.4272 to 0.4331 in.) | |
| Minimum | 10.70 mm (0.4213 in.) | ||
| Chain | Elongation | Minimum | 136.9 mm (5.389 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 | 22.987 to 23.000 mm (0.9050 to 0.9055 in.) | |
| Idle gear inside diameter | 23.02 to 23.03 mm (0.9062 to 0.9067 in.) | ||
| Oil clearance | Standard | 0.02 to 0.043 mm (0.0001 to 0.0017 in.) | |
| Maximum | 0.093 mm (0.0037 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.) | |
| Cylinder head sub-assembly | Standard warpage | Cylinder head lower side | 0.05 mm (0.0020 in.) |
| Intake side | 0.08 mm (0.0031 in.) | ||
| Exhaust side | 0.08 mm (0.0031 in.) | ||
| Maximum warpage | 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 (0.0394 in.) | |
| Maximum | 0.50 mm (00.197 in.) | ||
| Overall length | Standard | 105.85 mm (4.1673 in.) | |
| Maximum | 105.35 mm (4.1476 in.) | ||
| Exhaust valve | Valve stem diameter | 5.465 to 5.480 mm (0.2151 to 0.2157 in.) | |
| Margin thickness | Standard | 1.0 mm (0.0394 in.) | |
| Maximum | 0.50 mm (00.197 in.) | ||
| Overall length | Standard | 111.40 mm (4.3464 in.) | |
| Maximum | 109.90 mm (4.3268 in.) | ||
| Inner compression spring | Free length | 49.73 mm (1.958 in.) | |
| Deviation | Maximum | 1.0 mm (0.039 in.) | |
| Angle (reference) | Maximum | 2° | |
| Intake valve guide bush | Inside diameter | 5.51 to 5.53 mm (0.2169 to 0.2177 in.) | |
| Oil clearance | Standard | 0.030 to 0.060 mm (0.0012 to 0.0024 in.) | |
| Maximum | 0.08 mm (0.0032 in.) | ||
| Bush bore diameter | Use STD | 10.333 to 10.344 (0.4069 to 0.4072 in.) | |
| Use O/S 0.05 | 10.383 to 10.394 mm (0.4088 to 0.4092 in.) | ||
| Protrusion height | 9.30 to 9.70mm (0.3661 to 0.3819 in.) | ||
| Exhaust valve guide bush | Inside diameter | 5.510 to 5.530 mm (0.2169 to 0.2177 in.) | |
| Oil clearance | Standard | 0.025 to 0.065 mm (0.0010 to 0.0026 in.) | |
| Maximum | 0.01 mm (0.00039 in.) | ||
| Bush bore diameter | Use STD | 10.333 to 10.344 (0.4069 to 0.4072 in.) | |
| Use O/S 0.05 | 10.383 to 10.394 mm (0.4088 to 0.4092 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.) | |
| Standard cam lobe height | Intake | 44.318 to 44.418 mm (1.7448 to 1.7487 in.) | |
| Exhaust | 44.341 to 44.441 mm (1.7457 to 1.7496 in.) | ||
| Maximum cam lobe height | Intake | 44.168 mm (1.7389 in.) | |
| Exhaust | 44.191 mm (1.7398 in.) | ||
| Oil clearance | Standard No. 1 journal | 0.031 to 0.078 mm (0.0012 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 (0.006 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.) | |
| Standard cam lobe height | Intake | 44.318 to 44.418 mm (1.7448 to 1.7487 in.) | |
| Exhaust | 44.341 to 44.441 mm (1.7457 to 1.7496 in.) | ||
| Maximum cam lobe height | Intake | 44.168 mm (1.7389 in.) | |
| Exhaust | 44.191 mm (1.7398 in.) | ||
| Oil clearance | Standard No. 1 journal | 0.031 to 0.078 mm (0.0012 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 (0.006 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.) | |
| Standard cam lobe height | Intake | 44.318 to 44.418 mm (1.7448 to 1.7487 in.) | |
| Exhaust | 44.341 to 44.441 mm (1.7457 to 1.7496 in.) | ||
| Maximum cam lobe height | Intake | 44.168 mm (1.7389 in.) | |
| Exhaust | 44.191 mm (1.7398 in.) | ||
| Oil clearance | Standard No. 1 journal | 0.031 to 0.078 mm (0.0012 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 (0.006 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.) | |
| Standard cam lobe height | Intake | 44.318 to 44.418 mm (1.7448 to 1.7487 in.) | |
| Exhaust | 44.341 to 44.441 mm (1.7457 to 1.7496 in.) | ||
| Maximum cam lobe height | Intake | 44.168 mm (1.7389 in.) | |
| Exhaust | 44.191 mm (1.7398 in.) | ||
| Oil clearance | Standard No. 1 journal | 0.031 to 0.078 mm (0.0012 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 (0.006 in.) | ||
| Ring pin for cylinder head sub-assembly | Protrusion height | 2.5 to 3.8 mm (0.098 to 0.150 in.) | |
| Straight pin for cylinder head sub-assembly | 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 (0.0197 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 bush bore diameter | Use standard | 10.285 to 10.306 mm (0.4049 to 0.4057 in.) | |
| Use O/S 0.05 | 10.383 to 10.394 mm (0.40889 to 0.4092 in.) | ||
| Piston diameter | Distance | 9.1 mm (0.36 in.) | |
| Standard | 93.960 to 93.980 mm (3.6992 to 3.6999 in.) | ||
| Maximum | 93.830 mm (3.6941 in.) | ||
| Piston oil clearance | Standard | 0.040 to 0.062 mm (0.00158 to 0.00244 in.) | |
| Maximum | 0.09 mm (0.0035 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 (-0.00007 to 0.0001 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: 22.008 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 0.070 mm (0.0008 to 0.0028 in.) | ||
| Piston ring end gap | Standard No. 1 | 0.23 to 0.33 mm (0.0091 to 0.0130 in.) | |
| No. 2 | 0.35 to 0.45 mm (0.0138 to 0.0177 in.) | ||
| Oil (Side rail) | 0.10 to 0.40 mm (0.0039 to 0.0157 in.) | ||
| Maximum No. 1 | 0.40 mm (0.0157 in.) | ||
| No. 2 | 0.50 mm (0.0197 in.) | ||
| Oil (Side rail) | 0.45 mm (0.0177 in.) | ||
| Connecting rod bolt diameter | Standard | 8.5 to 8.6 mm (0.335 to 0.339 in.) | |
| Minimum | 8.3 mm (0.327 in.) | ||
| Crank shaft bearing cap set bolt diameter | Standard | 10.8 to 11.0 mm (0.4252 to 0.4331 in.) | |
| Minimum | 10.70 mm (0.4213 in.) | ||
| Crankshaft circle runout | Maximum | 0.06 mm (0.0024 in.) | |
| Main journal diameter | 60.988 to 61.00 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 sub-assembly | Protrusion height | Pin A | 6 mm (0.24 in.) |
| Pin B | 23 mm (0.91 in.) | ||
| Pin C | 11 mm (0.43 in.) | ||
| Pin D | 9 mm (0.35 in.) | ||
| Tight plug for cylinder block | Depth | 0.2 to 1.2 mm (0.007 to 0.047 in.) | |
ENGINE UNIT