Engine Electrical

Item	Measurement	Qualification	Standard or New	Service Limit
Ignition coil	Rated voltage		12 V
	Firing order		1-3-4-2
Spark plug	Type		NGK: BKR6E-11 DENSO: K20PR-U11
	Gap		1.0-1.1 mm (0.039-0.043 in.)	———
Ignition timing		At idle (check the red mark)	M/T (in neutral): 8±2° BTDC at 650±50 rpm (min-1)
			CVT (in [N] or [P]): 8±2° BTDC at 750±50 rpm (min-1)
Drive belt NOTE: Adjust a new belt to the new belt spec., run the engine for 5 minutes, then readjust it to the used belt spec.	Deflection with 98 N (10 kgf, 22 lbs) applied mid way between pulleys	Without A/C (with A/C, see ‘‘Compressor belt'' in the A/C table)	Used belt: 7.5-10.5 mm (0.30-0.41 in.)
			New belt: 4.5-6.0 mm (0.18-0.24 in.)
	Tension (measured with belt tension gauge)	Without A/C (with A/C, see ‘‘Compressor belt'' in the A/C table)	Used belt: 440-590 N (45-60 kgf, 99-130 lbs)
			New belt: 981-1,130 N (100-115 kgf, 220-254 lbs)
Alternator	Output	At 13.5 V and normal engine temperature	75 A
	Coil (rotor) resistance	at 20°C (68°F)	2.6-2.9 W
	Slip ring O.D.		22.7 mm (0.89 in.)	21.7 mm (0.85 in.)
	Brush length		19.0 mm (0.75 in.)	5 mm (0.20 in.)
	Brush spring tension		3.3-4.1 N (0.34-0.42 kgf, 0.7-0.9 lbs)
Starter	Output		0.6 kw
	Commutator mica depth		0.45-0.75 mm (0.018-0.030 in.)	0.2 mm (0.008 in.)
	Commutator runout		0.05 mm (0.002 in.) max.	0.4 mm (0.02 in.)
	Commutator O.D.		27.9-28.0 mm (1.098-1.102 in.)	27.0 mm (1.06 in.)
	Brush length		9.7-10.3 mm (0.38-0.41 in.)	6 mm (0.2 in.)

Engine Assembly

Item	Measurement	Qualification	Standard or New	Service Limit
Compression	Pressure check at 250 rpm (min-1) with wide open throttle. (See Design Specs for ratio)	Minimum	980 kPa (10.0 kgf/cm2, 142 psi)	———
		Maximum variation	200 kPa (2.0 kgf/cm2, 28 psi)	———

Cylinder Head

Item	Measurement	Qualification	Standard or New	Service Limit
Head	Warpage		———	0.08 mm (0.003 in.)
	Height		119.9-120.1 mm (4.720-4.728 in.)	———
Camshaft	End play		0.05-0.25 mm (0.002-0.010 in.)	0.5 mm (0.02 in.)
	Camshaft-to-holder oil clearance		0.045-0.084 mm (0.0018-0.0033 in.)	0.100 mm (0.004 in.)
	Total runout		0.03 mm (0.001 in.) max.	0.04 mm (0.002 in.)
	Cam lobe height	Intake	35.471 mm (1.3965 in.)	———
		Exhaust	35.358 mm (1.3920 in.)	———
Valve	Clearance (cold)	Intake	0.15-0.19 mm (0.006-0.007 in.)	———
		Exhaust	0.26-0.30 mm (0.010-0.012 in.)	———
	Stem O.D.	Intake	5.48-5.49 mm (0.216-0.216 in.)	5.45 mm (0.215 in.)
		Exhaust	5.45-5.46 mm (0.215-0.215 in.)	5.42 mm (0.213 in.)
	Stem-to-guide clearance	Intake	0.020-0.050 mm (0.0008-0.0020 in.)	0.08 mm (0.003 in.)
		Exhaust	0.050-0.080 mm (0.0020-0.0031 in.)	0.11 mm (0.004 in.)
Valve seats	Width	Intake	0.850-1.150 mm (0.0335-0.0453 in.)	1.60 mm (0.063 in.)
		Exhaust	1.25-1.550 mm (0.0492-0.0610 in.)	2.00 mm (0.079 in.)
	Stem installed height	Intake	46.1-46.5 mm (1.815-1.831 in.)	46.8 mm (1.843 in.)
		Exhaust	46.2-46.6 mm (1.819-1.835 in.)	46.9 mm (1.846 in.)
Valve springs	Free length	Intake	50.52 mm (1.989 in.)	———
		Exhaust	57.37 mm (2.259 in.)	———
Valve guides	I.D.	Intake	5.51-5.53 mm (0.217-0.218 in.)	5.55 mm (0.219 in.)
		Exhaust	5.51-5.53 mm (0.217-0.218 in.)	5.55 mm (0.219 in.)
	Installed height	Intake	15.85-16.35 mm (0.624-0.644 in.)	———
		Exhaust	15.85-16.35 mm (0.624-0.644 in.)	———
Rocker arms	Arm-to-shaft clearance	Intake	0.019-0.058 mm (0.0007-0.0023 in.)	0.08 mm (0.003 in.)
		Exhaust	0.019-0.058 mm (0.0007-0.0023 in.)	0.08 mm (0.003 in.)

Engine Block

Item	Measurement	Qualification	Standard or New	Service Limit
Block	Warpage of deck		0.07 mm (0.003 in.) max.	0.10 mm (0.004 in.)
	Bore diameter		73.00-73.02 mm (2.874-2.875 in.)	73.07 mm (2.877 in.)
	Bore taper		———	0.05 mm (0.002 in.)
	Reboring limit		———	0.25 mm (0.01 in.)
Piston	Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt		72.98-72.99 mm (2.873-2.874 in.)	72.97 mm (2.873 in.)
	Clearance in cylinder		0.010-0.040 mm (0.0004-0.0016 in.)	0.05 mm (0.002 in.)
	Ring groove width	Top	1.040-1.050 mm (0.0409-0.0413 in.)	1.07 mm (0.042 in.)
		Second	1.220-1.230 mm (0.0481-0.0484 in.)	1.250 mm (0.0492 in)
		Oil	2.005-2.020 mm (0.0789-0.0795 in.)	2.050 mm (0.0807 in.)
Piston ring	Ring-to-groove clearance	Top	0.055-0.080 mm (0.0022-0.0031 in.)	0.15 mm (0.006 in.)
		Second	0.030-0.055 mm (0.0012-0.0022 in.)	0.13 mm (0.005 in.)
	Ring end gap	Top	0.15-0.30 mm (0.006-0.012 in.)	0.60 mm (0.024 in.)
		Second	0.35-0.50 mm (0.014-0.020 in.)	0.65 mm (0.026 in.)
		Oil	0.20-0.70 mm (0.008-0.028 in.)	0.80 mm (0.031 in.)
Piston pin	O.D.		17.997-18.000 mm (0.7085-0.7087 in.)	———
	Pin-to-piston clearance		0.010-0.017 mm (0.0004-0.0007 in.)	———
Connecting rod	Pin-to-rod interferemce		0.020-0.036 mm (0.0008-0.0014 in.)	———
	Small-end bore diameter		17.964-17.977 mm (0.707-0.708 in.)	———
	Large-end bore diameter	Nominal	43.0 mm (1.69 in.)	———
	End play installed on crankshaft		0.15-0.30 mm (0.006-0.012 in.)	0.40 mm (0.016 in.)
Crankshaft	Main journal diameter		49.976-50.000 mm (1.9676-1.9685 in.)	———
	Rod journal diameter		39.976-40.000 mm (1.5739-1.5748 in.)	———
	Rod/main journal taper		0.005 mm (0.0002 in.)	0.010 mm (0.0004 in.)
	Rod/main journal out-of-round		0.005 mm (0.0002 in.)	0.010 mm (0.0004 in.)
	End play		0.10-0.35 mm (0.004-0.014 in.)	0.45 mm (0.018 in.)
	Runout		0.03 mm (0.0012 in.) max.	0.04 mm (0.0016 in.)
Crankshaft bearings	Main bearing-to-journal oil clearance		0.018-0.036 mm (0.0007-0.0014 in.)	0.05 mm (0.0020 in.)
	Rod bearing clearance		0.020-0.038 mm (0.0008-0.0015 in.)	0.05 mm (0.0020 in.)

Engine Lubrication

Item	Measurement	Qualification	Standard or New	Service Limit
Engine oil	Capacity	Engine overhaul	4.2 [liter] (4.4 US qt, 3.7 lmp qt)	———
		Oil change including oil filter	3.6 [liter] (3.8 US qt, 3.2 lmp qt)	———
		Oil change without oil filter	3.4 [liter] (3.6 US qt, 3.0 lmp qt)	———
Oil pump	Inner rotor-to-outer rotor clearance		0.02-0.14 mm (0.001-0.006 in.)	0.20 mm (0.008 in.)
	Pump housing-to-outer rotor clearance		0.10-0.18 mm (0.004-0.007 in.)	0.20 mm (0.008 in.)
	Pump housing-to-rotor axial clearance		0.02-0.07 mm (0.001-0.003 in.)	0.15 mm (0.006 in.)
Relief valve	Relief valve, oil pressure with oil temperature at 80°C (176°F)	At idle	70 kPa (0.7 kgf/cm2, 10 psi) min.	———
		At 3,000 rpm (min-1)	340 kPa (3.5 kgf/cm2, 50 psi) min.	———

Cooling

Item	Measurement	Qualification	Standard or New	Service Limit
Radiator	Coolant capacity (Includes engine, heater, hoses, and reservoir)	Engine overhaul	4.7 [liter] (5.0 US qt, 4.1 lmp qt)
		Coolant change	3.6 [liter] (3.8 US qt, 3.2 lmp qt)
Reservoir	Coolant capacity		0.4 [liter] (0.4 US qt, 0.4 lmp qt)
Radiator cap	Opening pressure		93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)
Thermostat	Opening temperature	Begins to open	80-84°C (176-183°F)
		Fully open	95°C (203°F)
	Valve lift at fully open		8.0 mm (0.31 in.) min.
Thermoswitch	Switching temperature	Turns ON	91-95°C (196-203°F)
		Turns OFF	Subtract 3-8°C (5-15°F) from actual ON temperature

Fuel and Emissions

Item	Measurement	Qualification	Standard or New	Service Limit
Fuel pressure regulator	Pressure with fuel pressure gauge connected		320-370 kPa (3.3-3.8 kgf/cm2, 47-52 psi)
Fuel tank	Capacity		42[liter] (11 US gal, 9 lmp gal)
Engine idle	Idle speed without a load	M/T in neutral	650±50 rpm(min-1)
		CVT in [N] or [P] position	750±50 rpm(min-1)
	Fast idle speed	M/T in neutral	1,500±200 rpm(min-1)
		CVT in [N] or [P] position	1,500±200 rpm(min-1)
	Idle CO		0.1 % max.

Clutch

Item	Measurement	Qualification	Standard or New		Service Limit
Clutch pedal	Height form floor	LHD model	163 mm (6.4 in.)		———
		RHD model	150 mm (5.9 in.)		———
	Stroke		130-140 mm (5.12-5.51 in.)		———
	Play		6-20 mm (0.2-0.8 in.)		———
	Disengagement height from the floor	LHD model	72 mm (2.8 in.)min.		———
		RHD model	61 mm (2.4 in.)min.		———
Flywheel	Runout on clutch mating surface		0.05 mm (0.002 in.) max.		0.15 mm (0.006 in.)
Clutch disc	Rivet head depth		1.1-1.6 mm (0.043-0.063 in.)		0.2 mm (0.08 in.)
	Thickness		7.25-7.95 mm (0.29-0.31 in.)		5.0 mm (0.20 in.)
Pressure plate	Warpage		0.03 mm (0.001 in.) max.		0.15 mm (0.006 in.)
	Height of diaphragm spring fingers	Measure with feeler gauge and special tool	0.8 mm (0.03 in.) max.		1.0 mm (0.04 in.)