EG1–77 – ENGINE MECHANICAL SERVICE SPECIFICATIONS

ENGINE ? ENGINE MECHANICAL

SERVICE SPECIFICATIONS

SERVICE DATA

Compression pressure Cylinder head

Valve guide bushing

Valve

Valve spring

Rocker arm and shaft Intake, exhaust manifolds and air intake chamber

STD

Limit

Difference between each cylinder Head surface warpage Manifold surface warpage

Limit Limit

Valve seat Refacing angle

Intake

Exhaust

Contacting angle

Contacting width

Inner diameter Outer diameter

Intake Exhaust STD

O/S 0.05

Replacing temperature (cylinder head side)

Valve overall length

STD

Intake

Valve face angle

Exhaust

Stem diameter

STD

Intake

Stem end refacing Stem oil clearance

Limit STD

Exhaust STD Intake

Exhaust

Limit Intake

Exhaust

Valve head edge thickness

STD

Free length

Limit

Installed load at 40.5 mm (1.594 in.)

STD

Squareness

Limit Limit

Rocker arm inside diameter

Rocker shaft diameter

Shaft to arm oil clearance

STD

Limit

Manifold surface warpage Limit Intake Exhaust Air intake chamber

Chain and sprocket

Crankshaft sprocket wear Camshaft sprocket wear

Limit Limit

EG1?77

EG1?78

ENGINE ? ENGINE MECHANICAL

Tension and damper

Camshaft

Tensioner head thickness No. 1 damper wear No. 2 damper wear Thrust clearance

Journal oil clearance

Journal diameter Circle runout Cam height

Limit Limit Limit STD Limit STD Limit STD Limit STD

Limit

Cylinder block

Cylinder head surface warpage Cylinder bore STD

Intake Exhaust Intake Exhaust

Cylinder bore wear Cylinder block main journal bore

STD

Limit

Piston and piston ring

Piston diameter

STD

Piston to cylinder clearance Ring to ring groove clearance

Piston ring end gap

STD Limit STD

Limit

Connecting rod and bearing

Piston pin installing temperature

Thrust clearance

STD

Limit

Bearing oil clearance

STD

Limit

ENGINE ? ENGINE MECHANICAL

Connecting rod and bearing (cont'd)

Big end inner diameter Connecting rod bearing center wall thickness

Crankshaft

Pin to bushing oil clearance

Rod bend per 100 mm (3.94 in.) Rod twist per 100 mm (3.94 in.) Thrust clearance Thrust washer thickness

STD Limit

Limit

Limit STD Limit STD

Main journal oil clearance

Main journal diameter Main journal finished diameter

STD Limit STD

Main bearing center wall thickness STD

Crank pin diameter

STD

Crank pin finished diameter

U/S 0.25

Circle runout Limit

Main journal taper and out?of?round

Limit

Crank pin journal taper and out?of round

Limit

EG1?79

EG1?80

ENGINE ? ENGINE MECHANICAL

TORQUE SPECIFICATIONS

Part tightened Cylinder head x Cylinder head cover Cylinder head x Camshaft bearing cap Cylinder head x Spark plug Cylinder head x Intake manifold Cylinder head x No. 1 secondary air injection manifold Cylinder head x EGR valve Cylinder head x Exhaust manifold Cylinder head x Cylinder head rear cover Cylinder block x Cylinder head Cylinder block x Chain damper Cylinder block x Chain tensioner Cylinder block x Engine mounting Cylinder block x Rear oil seal retainer Cylinder block x Fuel filter bracket Oil cooler relief valve x Cylinder block Cylinder block x Crankshaft bearing cap Cylinder block x Oil strainer Cylinder block x Oil pan Cylinder block x Engine mounting bracket Valve clearance adjusting screw Camshaft x Distributor drive gear Crankshaft pulley x No. 2 crankshaft pulley Air intake chamber x EGR pipe Air intake chamber x Intake manifold Air intake chamber x Accelerator control cable bracket Intake manifold x Water outlet Intake manifold x PAIR valve No. 1 secondary air injection manifold x PAIR valve No. 1 secondary air injection manifold x No. 2 secondary air injection manifold

Exhaust manifold x No. 2 exhaust manifold heat insulator Exhaust manifold x No. 2 secondary air injection manifold

10 mm bolt 8 mm bolt

Connecting rod x Connecting rod cap Crankshaft x Crankshaft pulley Crankshaft x Flywheel Crankshaft x Drive plate Oil pan x Drain plug

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