ENGINE UNIT
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 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 (0.020 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 sub-assembly
| 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.)
|
