Service Data

Engine Mechanical Service Data Specification (1 Of 3)

Ignition timing	w/ Terminal TC and CG of DLC3 connected	8 - 12° BTDC
Ignition timing	W/ Terminal TC and CG of DLC3 disconnected	10 - 18° BTDC
Idle speed		650 - 750 rpm
Compression
Compression pressure		1,300 kPa (13.3 kgfcm² ' 189 psi)
Minimum pressure		1,000 kPa (10.2 kgfcm² ' 145 psi)
Difference between each cylinder		100 kPa (1.0 kgfcm² ' 15 psi)
Cylinder head set bolt Length	Standard	146.8 - 148.2 mm (5.780 - 5.835 in.)
Cylinder head set bolt Length	Maximum	148.5 mm (5.846 in.)
Valve clearance (Cold)
No. 1 Cylinder TDC/Compression	Intake	0.15 - 0.25 mm (0.0059 - 0.0098 in.)
Exhaust		0.25 - 0.35 mm (0.0098 - 0.0138 in.)
No. 4 Cylinder TDC/Compression	Intake	0.15 - 0.25 mm (0.0059 - 0.0098 in.)
No. 4 Cylinder TDC/Compression	Exhaust	0.25 - 0.35 mm (0.0098 - 0.0138 in.)
Chain elongation	Maximum	122.6 mm (4.827 in.)
Camshaft timing gear diameter (w/ chain)	Minimum	97.3 mm (3.831 in.)
Crankshaft timing gear Diameter (w/ chain)	Minimum	51.6 mm (2.032 in.)
Chain tensioner slipper wear	Maximum	1.0 mm (0.039 in.)
Chain vibration damper wear	Maximum	1.0 mm (0.039 in.)
Camshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Cam lob height	Standard Intake	44.333 - 44.433 mm (1.7454 - 1.7493 in.)
	Exhaust	43.761 - 43.861 mm (1.7229 - 1.7268 in.)
	Minimum Intake	44.18 mm (1.7394 in.)
	Exhaust	43.61 mm (1.7169 in.)
Journal diameter	No. 1	34.449 - 34.465 mm (1.3563 - 1.3569 in.)
Journal diameter	Others	22.949 - 22.965 mm (0.9035 - 0.9041 in.)
Cylinder head warpage	Cylinder block side	0.05 mm (0.0020 in.)
	Intake manifold side	0.10 mm (0.0039 in.)
	Exhaust manifold side	0.10 mm (0.0039 in.)
Camshaft thrust clearance	Standard	0.040 - 0.095 mm (0.0016 - 0.0037 in.)
Camshaft thrust clearance	Maximum	0.110 mm (0.0043 in.)
Camshaft oil clearance	Standard	0.035 - 0.072 mm (0.0014 - 0.0028 in.)
Camshaft oil clearance	Maximum	0.10 mm (0.0039 in.)
Valve lifter diameter		30.966 - 30.976 mm (1.2191 - 1.2195 in.)
Valve lifter bore diameter		31.000 - 31.025 mm (1.2205 - 1.2215 in.)
Valve lifter oil clearance	Standard	0.024 - 0.059 mm (0.0009 - 0.0023 in.)
Valve lifter oil clearance	Maximum	0.079 mm (0.0031 in.)
Inner compression spring
Free length		43.40 mm (1.7087 in.)
Deviation		1.6 mm (0.063 in.)
Angle (reference)		2°
Installed tension	at 33.6 mm (1.323 in.)	158.6 - 175.4 N (16.2 - 17.9 kgf, 35.7 - 39.5 lbf)
Maximum working tension	at 24.1 mm (0.949 in.)	335.3 - 370.7 N (34.2 - 37.8 kgf, 75.4 - 83.3 lbf)
Valve
Overall length	Standard Intake	88.65 mm (3.4902 in.)
Exhaust		88.69 mm (3.4917 in.)
Minimum Intake		88.35 mm (3.4784 in.)
Exhaust		88.39 mm (3.4799 in.)
Valve stem diameter	Intake	5.470 - 5.485 mm (0.2154 - 0.2159 in.)
Exhaust		5.465 - 5.480 mm (0.2152 - 0.2158 in.)
Margin thickness	Standard	1.0 mm (0.039 in.)
Minimum		0.7 mm (0.028 in.)
Valve guide bushing inside diameter		5.510 - 5.530 mm (0.2169 - 0.2177 in.)

Engine Mechanical Service Data Specification (2 Of 3)

Valve guide Bushing oil clearance	Standard 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 (0.0032 in.)
	Exhaust	0.10 mm (0.0039 in.)
Valve guide bushing bore diameter	STD	10.285 - 10.306 mm (0.4049 - 0.4058 in.)
Valve guide bushing bore diameter	O/S 0.05	10.335 - 10.356 mm (0.4069 - 0.4077 in.)
Valve guide bushing protrusion height		8.7-9.1 mm (0.343 - 0.358 in.)
Straight pin protrusion height (cylinder head)		5 mm (0.197 in.)
Union protrusion height	A	29 mm (1.142 in.)
	B	66.5 mm (2.618 in.)
	C	24 mm (0.945 in.)
Connecting rod thrust clearance	Standard	0.160 - 0.342 mm (0.063 - 0.135 in.)
Connecting rod thrust clearance	Maximum	0.342 mm (0.135 in.)
Connecting rod oil clearance	Standard	0.028 - 0.060 mm (0.0011 - 0.0024 in.)
Connecting rod oil clearance	Maximum	0.080 mm (0.0032 in.)
Connecting rod large end bore diameter	1	47.000 - 47.008 mm (1.85039 - 1.85071 in.)
	2	47.009 - 47.016 mm (1.85075 - 1.85102 in.)
	3	47.017 - 47.024 mm (1.85106 - 1.85134 in.)
Connecting rod bearing thickness	1	1.486 - 1.490 mm (0.05850 - 0.05866 in.)
	2	1.491 - 1.494 mm (0.05870 - 0.05882 in.)
	3	1.495 - 1.498 mm (0.05886 - 0.05898 in.)
Crankshaft pin outer diameter		43.992 - 44.000 mm (1.73197 - 1.73228 in.)
Crankshaft thrust clearance	Standard	0.04 - 0.24 mm (0.0016 - 0.0095 in.)
Crankshaft thrust clearance	Maximum	0.30 mm (0.0118 in.)
Cylinder block warpage	Maximum	0.05 mm (0.0020 in.)
Cylinder bore diameter		79.000 - 79.013 mm (3.1102 - 3.1108 in.)
Piston diameter	at 25.6 mm (1.008 in.) from piston head	78.872 - 78.972 mm (3.1052 - 3.1091 in.)
Piston oil clearance	Standard	0.065 - 0.088 mm (0.0026 - 0.0035 in.)
Piston oil clearance	Maximum	0.088 mm (0.0035 in.)
Piston pin bore diameter	A	20.006 - 20.009 mm (0.78764 - 0.78776 in.)
	B	20.010 - 20.012 mm (0.78780 - 0.78787 in.)
	C	20.013 - 20.01b mm (0.78791 - 0/8/99 in.)
Piston pin outer diameter	A	20.004 - 20.007 mm (0.78756 - 0.78768 in.)
	B	20.008 - 20.010 mm (0.78772 - 0.78780 in.)
	C	20.011 - 20.013 mm (0.78783 - 0.78791 in.)
Connecting rod small end bore diameter	A	20.012 - 20.015 mm (0.78787 - 0.78799 in.)
	B	20.016 - 20.018 mm (0.78803 - 0.78811 in.)
	C	20.019 - 20.021 mm (0.78815 - 0.78823 in.)
Piston pin oil clearance
Piston pin x Piston	Standard	0.002 - 0.011 mm (0.0001 - 0.0004 in.)
Maximum		0.011 mm (0.0004 in.)
Piston pin x Connecting rod	Standard	- 0.001 - 0.017 mm (- 0.00004 - 0.0007 in.)
Maximum		0.017 mm (0.0007 in.)
Ring groove clearance	No. 1	0.020 - 0.070 mm (0.0008 - 0.0028 in.)
	No. 2	0.030 - 0.070 mm (0.0012 - 0.0028 in.)
	Oil	0.03 - 0.11 mm (0.0012 - 0.0043 in.)
Piston ring end gap	Standard No. 1	0.25 - 0.35 mm (0.0098 - 0.0138 in.)
	No. 2	0.35 - 0.50 mm (0.0138 - 0.0197 in.)
	Oil	0.15 - 0.40 (0.0059 - 0.158 in.)
	Maximum No. 1	1.05 mm (0.0413 in.)
	No. 2	1.20 mm (0.0 - 172 in.)
Connecting rod
Out-of alignment	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Twist	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod bolt diameter	Standard	6.6 - 6.7 mm (0.260 - 0.264 in.)
	Maximum	6.4 mm (0.252 in.)

Engine Mechanical Service Data Specification (3 Of 3)

Crankshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Main journal diameter		47.988 - 48.000 mm (1.8893 - 1.8898 in.)
Taper and out-of-round	Maximum	0.020 mm (0.0008 in.)
Crank pin diameter		43.992 - 44.000 mm (1.7320 - 1.7323 in.)
Taper and out-of-round	Maximum	0.020 mm (0.0008 in.)
Crankshaft bearing cap set bolt diameter	Standard	7.3 - 7.5 mm (0.287 - 0.295 in.)
Crankshaft bearing cap set bolt diameter	Minimum	7.3 mm (0.287 in.)
Crankshaft oil clearance	Standard	0.015 - 0.032 mm (0.0006 - 0.0013 in.)
Crankshaft oil clearance	Minimum	0.05 mm (0.0020 in.)
Cylinder block journal bore diameter	0	52.000 - 52.002 mm (2.04724 - 2.04732 in.)
	1	52.003 - 52.004 mm (2.04736 - 2.04740 in.)
	2	52.005 - 52.006 mm (2.04744 - 2.04748 in.)
	3	52.007 - 52.009 mm (2.04752 - 2.04760 in.)
	4	52.010-52.011 mm (2.04764 - 2.04768 in.)
	5	52.012 - 52.013 mm (2.04772 - 2.04776 in.)
	6	52.014 - 52.015 mm (2.04788 - 2.04783 in.)
Crankshaft journal diameter	0	47.999 - 48.000 mm (1.88972 - 1.88976 in.)
	1	47.997 - 47.998 mm (1.88965 - 1.88969 in.)
	2	47.995 - 47.996 mm (1.88957 - 1.88961 in.)
	3	47.993 - 47.994 mm (1.88949 - 1.88953 in.)
	4	47.991 - 47.992 mm (1.88941 - 1.88945 in.)
	5	47.988 - 47.990 mm (1.88929 - 1.88922 in.)
Standard bearing center wall thickness	1	1.994 - 1.997 mm (0.07850 - 0.07862 in.)
	2	1.998 - 2.000 mm (0.07866 - 0.07874 in.)
	3	2.001 - 2.003 mm (0.07878 - 0.07886 in.)
	4	2.004 - 2.006 mm (0.07890 - 0.07898 in.)
Straight pin (Cylinder block)	A	5 mm (0.200 in.)
	B	7.5 mm (0.295 in.)
	C	12 mm (0.472 in.)
	D	8 mm (0.315 in.)
Ring pin (Cylinder block)	A	6 mm (0.236 in.)
	B	7 mm (0.276 in.)
	C	10 mm (0.394 in.)