Group_02_Specifications.pdf

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Ignition coil
Rated voltage
12 V
Firing order
1 - 3 - 4 - 2
Spark plug
Type
NGK: ZFR6K-11
DENSO: KJ20DR-M11
Gap
1.0 - 1.1 mm (0.039 - 0.043 in.)
———
Ignition timing
At idle (check the
UHG mark)
M/T (in neutral): 8 ± 2° BTDC at 650 ± 50 rpm (min -1 )
A/T (in [1] or [3]): 8 ± 2° BTDC at 650 ± 50 rpm (min -1 )
Alternator
Output
At 13.5 V and
normal engine
temperature
90 A
Coil (rotor) resistance
at 20 C° (68 F°)
1.84 - 2.10 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.)
5.0 mm (0.20 in.)
Brush spring tension
3.3 - 4.1 N (0.34 - 0.42 kgf, 0.7 - 0.9 lbs)
Starter
(MITSUBA)
Output
1.2 kW, 1.6 kW
Commutator mica depth
0.4 - 0.5 mm (0.016 - 0.020 in.)
0.15 mm (0.006 in.)
Commutator runout
0.02 mm (0.001 in.) max.
0.05 mm (0.002 in.)
Commutator O.D.
28.0 - 28.1 mm (1.102 - 1.106 in.)
27.5 mm (1.083 in.)
Brush length
11.1 - 11.5 mm (0.44 - 0.45 in.)
4.3 mm (0.17 in.)
Starter
(DENSO)
Output
1.0 kW, 1.1 kW
Commutator mica depth
0.50 - 0.80 mm (0.020 - 0.031 in.)
0.2 mm (0.008 in.)
Commutator runout
0.02 mm (0.001 in.) max.
0.05 mm (0.002 in.)
Commutator O.D.
28.0 mm (1.10 in.)
27.0 mm (1.06 in.)
Brush length
14.0 - 14.5 mm (0.55 - 0.57 in.)
9.0 mm (0.35 in.)
Brush spring tension
13.7 - 17.7 N (1.40 - 1.80 kgf, 3.09 - 3.98 lbs)
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Compression
Pressure check at 250
(min -1 ) rpm with wide
open throttle. (See Design
Specs for ratio)
Minimum
930 kPa (9.5 kgf/cm 2 , 135 psi)
———
Maximum variation
200 kPa (2.0 kgf/cm 2 , 28 psi)
———
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Head
Warpage
———
0.05 mm (0.002 in.)
Height
103.95 - 104.05 mm
(4.093 - 4.096 in.)
———
Camshaft
End play
0.05 - 0.20 mm (0.002 - 0.008 in.)
0.4 mm (0.02 in.)
Camshaft-to-holder oil
clearance
No.1 journal
0.030 - 0.069 mm
(0.001 - 0.003 in.)
0.15 mm (0.006 in.)
No.2, 3, 4, 5
journals
0.060 - 0.099 mm
(0.002 - 0.004 in.)
0.15 mm (0.006 in.)
Total runout
0.03 mm (0.001 in.) max.
0.04 mm (0.002 in.)
Cam lobe height
Intake, primary
33.925 mm (1.3356 in.)
———
Intake, secondary
29.638 mm (1.1668 in.)
———
Exhaust
34.092 mm (1.3422 in.)
———
Valves
Clearance (cold)
Intake
0.21 - 0.25 mm (0.008 - 0.010 in.)
———
Exhaust
0.28 - 0.32 mm (0.011 - 0.013 in.)
———
Stem O.D.
Intake
5.475 - 5.485 mm (0.2156 - 0.2159 in.)
5.445 mm (0.214 in.)
Exhaust
5.450 - 5.460 mm (0.2146 - 0.2150 in.)
5.42 mm (0.213 in.)
Stem-to-guide clearance
Intake
0.030 - 0.055 mm (0.0012 - 0.0022 in.)
0.08 mm (0.003 in.)
Exhaust
0.055 - 0.080 mm (0.0022 - 0.0031 in.)
0.11 mm (0.004 in.)
Valve seats
Width
Intake
1.25 - 1.55 mm (0.049 - 0.061 in.)
2.00 mm (0.079 in.)
Exhaust
1.25 - 1.55 mm (0.049 - 0.061 in.)
2.00 mm (0.079 in.)
Stem installed height
Intake
40.8 - 41.0 mm (1.606 - 1.614 in.)
———
Exhaust
54.6 - 54.8 mm (2.150 - 2.157 in.)
———
Valve springs
Free length
Intake
47.61 mm (1.874 in.)
———
Exhaust
49.64 mm (1.954 in.)
49.63 mm (1.954 in.)
———
Valve guides
I.D.
Intake
5.515 - 5.530 mm
(0.2171 - 0.2177 in.)
5.55 mm (0.219 in.)
Exhaust
5.515 - 5.530 mm
(0.2171 - 0.2177 in.)
5.55 mm (0.219 in.)
Installed height
Intake
15.2 - 16.2 mm (0.598 - 0.638 in.)
———
Exhaust
15.5 - 16.5 mm (0.610 - 0.650 in.)
———
Rocker arms
Arm-to-shaft clearance
Intake
0.025 - 0.052 mm
(0.0010 - 0.0020 in.)
0.08 mm (0.003 in.)
Exhaust
0.018 - 0.056 mm
(0.0007 - 0.0022 in.)
0.08 mm (0.003 in.)
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Block
Warpage of deck
0.07 mm (0.003 in.) max.
0.10 mm (0.004 in.)
Bore diameter
(K20A4, K20A5 engines)
A or l
86.010 - 86.020 mm
(3.3862 - 3.3866 in.)
86.070 mm (3.3886 in.)
B or ll
86.000 - 86.010 mm
(3.3858 - 3.3862 in.)
86.070 mm (3.3886 in.)
Bore diameter
(K24A1 engines)
A or l
87.010 - 87.020 mm
(3.4256 - 3.4260 in.)
87.070 mm (3.4279 in.)
B or lI
87.000 - 87.010 mm
(3.4252 - 3.4256 in.)
87.070 mm (3.4279 in.)
Bore taper
———
0.05 mm (0.002 in.)
Reboring limit
———
0.25 mm (0.01 in.)
Piston
Skirt O.D. at 11 mm (0.4
in.) from bottom of skirt
(K20A4, K20A5 engines)
No letter or A
85.980 - 85.990 mm (3.3850 - 3.3854 in.) 85.930 mm (3.3831 in.)
Letter B
85.970 - 85.980 mm (3.3846 - 3.3850 in.) 85.920 mm (3.3827 in.)
Skirt O.D. at 13 mm (0.5
in.) from bottom of skirt
(K24A1 engine)
No letter or A
86.980 - 86.990 mm (3.4244 - v3.4248
in.)
86.930 mm (3.4224 in.)
Letter B
86.970 - 86.980 mm (3.4240 - 3.4244 in.) 86.920 mm (3.4220 in.)
Clearance in cylinder
0.020 - 0.040 mm (0.0008 - 0.0016 in.)
0.05 mm (0.002 in.)
Ring groove width
Top (K20A4, K20A5
engines)
1.220 - 1.230 mm (0.0481 - 0.0484 in.)
1.25 mm (0.049 in.)
Top (K24A1 engine) 1.230 - 1.240 mm (0.0484 - 0.0488 in.)
1.26 mm (0.0450 in.)
Second (K20A4,
K20A5 engines)
1.220 - 1.230 mm (0.0481 - 0.0484 in.)
1.25 mm (0.049 in.)
Second (K24A1
engine)
1.240 - 1.250 mm (0.0488 - 0.0492 in.)
1.270 mm (0.050 in.)
Oil (K20A4, K24A1
engines)
2.005 - 2.025 mm (0.0789 - 0.0797 in.)
2.05 mm (0.081 in.)
Oil (K20A5 engine)
2.805 - 2.825 mm (0.1104 - 0.1112 in.)
2.85 mm (0.112 in.)
Piston ring
Ring-to-groove clearance Top (K20A4 engine) 0.035 - 0.060 mm (0.0014 - 0.0024 in.)
0.13 mm (0.005 in.)
Top (K20A5 engine) 0.030 - 0.055 mm (0.0012 - 0.0022 in.)
0.13 mm (0.005 in.)
Top (K24A1 engine) 0.045 - 0.070 mm (0.0018 - 0.0028 in.)
0.13 mm (0.005 in.)
Second (K20A4,
K20A5 engines)
0.030 - 0.055 mm (0.0012 - 0.0022 in.)
0.13 mm (0.005 in.)
Second (K24A1
engine)
0.050 - 0.075 mm (0.0020 - 0.0030 in.)
0.13 mm (0.005 in.)
Ring end gap
Top
0.20 - 0.35 mm (0.008 - 0.014 in.)
0.60 mm (0.024 in.)
Second
0.40 - 0.55 mm (0.016 - 0.022 in.)
0.70 mm (0.028 in.)
Oil (K20A4 (Except
KY models) engine)
0.25 - 0.65 mm (0.010 - 0.026 in.)
0.75 mm (0.030 in.)
Oil (K20A4 (KY
model), K20A5,
K24A1 engines)
0.20 - 0.70 mm (0.008 - 0.028 in.)
0.80 mm (0.031 in.)
Piston pin
O.D.
21.961 - 21.965 mm (0.8646 - 0.8648 in.) 21.953 mm (0.8643 in.)
Pin-to-piston clearance
-0.005- +0.002 mm (-0.00020- + 0.00008
in.)
0.005 mm (0.0002 in.)
Connecting
rod
Pin-to-rod clearance
0.005 - 0.015 mm (0.0002 - 0.0006 in.)
0.02 mm (0.0008 in.)
Small-end bore diameter
21.970 - 21.976 mm (0.8650 - 0.8652 in.) ———
Large-end bore diameter
(Normal)
K20A4, K20A5
engines
48.0 mm (1.89 in.)
———
K24A1 engine
51.0 mm (2.01 in.)
———
End play installed on
crankshaft
0.15 - 0.30 mm (0.006 - 0.012 in.)
0.40 mm (0.016 in.)
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Crankshaft
Main journal diameter
No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal
54.984 - 55.008 mm (2.1648 - 2.1657 in.) ———
No. 3 journal
54.976 - 55.000 mm (2.1644 - 2.1654 in.) ———
Rod journal diameter
K20A4, K20A5
engines
44.976 - 45.000 mm (1.7707 - 1.7717 in.) ———
K24A1 engine
47.976 - 48.000 mm (1.8888 - 1.8898 in.) ———
Rod/main journal taper
0.005 mm (0.0002 in.) max.
0.010 mm (0.0004 in.)
Rod/main journal out-of-
round
0.005 mm (0.0002 in.) max.
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
No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal
0.017 - 0.041 mm (0.0007 - 0.0016 in.)
0.050 mm (0.0020 in.)
No. 3 journal
0.025 - 0.049 mm (0.0010 - 0.0019 in.)
0.055 mm (0.0022 in.)
Rod bearing clearance
0.021 - 0.049 mm (0.0008 - 0.0019 in.)
0.060 mm (0.0024 in.)
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Engine oil
Capacity
5.3
O
(5.6 US qt, 4.7 lmp qt) for engine overhaul
4.2
O
(4.4 US qt, 3.7 lmp qt) for oil change, including filter
4.0
O
(4.2 US qt, 3.5 lmp qt) for oil change, without filter
Oil pump
Inner-to-outer rotor
clearance
0.02 - 0.16 mm (0.001 - 0.006 in.)
0.20 mm (0.008 in.)
Pump housing-to-outer
rotor clearance
0.15 - 0.21 mm (0.006 - 0.008 in.)
0.23 mm (0.009 in.)
Pump housing-to-rotor
axial clearance
0.02 - 0.07 mm (0.001 - 0.003 in.)
0.12 mm (0.005 in.)
Balancer shafts, journal
diameter
No. 1 journal, front
shaft
19.938 - 19.950 mm (0.7850 - 0.7854 in.) 19.92 mm (0.784 in.)
No. 1 journal, rear
shaft
23.938 - 23.950 mm (0.9424 - 0.9429 in.) 23.92 mm (0.942 in.)
No. 2 journal, front
and rear shaft
32.949 - 32.961 mm (1.2972 - 1.2977 in.) 32.93 mm (1.296 in.)
Balancer shafts, journal
taper
0.005 mm (0.0002 in.) max.
———
Balancer shafts, end play Front
0.070 - 0.135 mm (0.0028 - 0.0053 in.)
0.15 mm (0.006 in.)
Rear
0.070 - 0.135 mm (0.0028 - 0.0053 in.)
0.15 mm (0.006 in.)
Balancer shafts, shaft-to-
bearing clearance
No. 1 journal, front
shaft
0.050 - 0.082 mm (0.0020 - 0.0032 in.)
0.10 mm (0.004 in.)
No. 1 journal, rear
shaft
0.050 - 0.082 mm (0.0020 - 0.0032 in.)
0.10 mm (0.004 in.)
No. 2 journal, front
and rear shaft
0.060 - 0.120 mm (0.0024 - 0.0047 in.)
0.15 mm (0.006 in.)
Balancer shaft bearings,
I.D.
No. 1 journal, front
shaft
20.000 - 20.020 mm (0.7874 - 0.7882 in.) 20.03 mm (0.789 in.)
No. 1 journal, rear
shaft
24.000 - 24.020 mm (0.9449 - 0.9457 in.) 24.03 mm (0.946 in.)
No. 2 journal, front
and rear shaft
33.021 - 33.069 mm (1.3000 - 1.3019 in.) 33.09 mm (1.303 in.)
Relief valve, oil pressure
with oil temperature at
80 °C (176 z°F)
At idle 70 kPa (0.7 kgf/cm 2 , 10 psi) min.
at 3,000 rpm (min -1 ) 300 kPa (3.1 kgf/cm 2 , 44 psi) min.
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