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: ZFR6K-11 DENSO: KJ20DR-M11
	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 idle
			A/T (in [N] or [P]): 8±2° BTDC at idle
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)
Starter (MITSUBISHI)	Output		1.7 kW
	Commutator mica depth		0.4-0.6 mm (0.016-0.024 in.)	0.2 mm (0.008 in.)
	Commutator runout		0.05 mm (0.002 in.) max.	0.1 mm (0.004 in.)
	Commutator O.D.		29.3-29.5 mm (1.154-1.161 in.)	28.8 mm (1.134 in.)
	Brush length		7.7-8.0 mm (0.30-0.31 in.)	0.9 mm (0.04 in.)

Engine Assembly

Item	Measurement	Qualification	Standard or New	Service Limit
Compression	Pressure check at 250 (min-1) rpm with wide open throttle. (See Design Specs for ratio)	Minimum	930 kPa (9.5 kgf/cm2, 135 psi)	———
		Maximum variation	200 kPa (2.0 kgf/cm2, 28 psi)	———

Cylinder Head

Item	Measurement	Qualification	Standard or New	Service Limit
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 (K20A6 engine)	Intake, primary	33.925 mm (1.3356 in.)	———
		Intake, secondary	29.638 mm (1.1668 in.)	———
		Exhaust	34.092 mm (1.3422 in.)	———
	Cam lobe height (K24A3 engine)	Intake, primary	33.416 mm (1.3156 in.)	———
		Intake, mid	35.032 mm (1.3792 in.)	———
		Intake, secondary	33.416 mm (1.3156 in.)	———
		Exhaust, primary	32.994 mm (1.2990 in.)	———
		Exhaust, mid	35.090 mm (1.3815 in.)	———
		Exhaust, secondary	32.994 mm (1.2990 in.)	———
Valves	Clearance (cold) (K20A6 engine)	Intake	0.21-0.25 mm (0.008-0.010 in.)	———
		Exhaust	0.28-0.32 mm (0.011-0.013 in.)	———
	Clearance (cold) (K24A3 engine)	Intake	0.21-0.25 mm (0.008-0.010 in.)	———
		Exhaust	0.25-0.29 mm (0.010-0.011 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	44.0-44.6 mm (1.73-1.76 in.)	———
		Exhaust	44.0-44.6 mm (1.73-1.76 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 (K20A6 engine)	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.)
	Arm-to-shaft clearance (K24A3 engine)	Intake	0.025-0.052 mm (0.0010-0.0020 in.)	0.08 mm (0.003 in.)
		Exhaust	0.025-0.052 mm (0.0010-0.0020 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 (K20A6 engine)	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 (K24A3 engine)	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 (K20A6 engine)	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 11 mm (0.4 in.) from bottom of skirt (K24A3 engine)	No letter or A	86.980-86.990 mm (3.4244-3.4248 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 (K20A6 engine)	1.240-1.250 mm (0.0488-0.0492 in.)	1.27 mm (0.050 in.)
		Top (K24A3 engine)	1.235-1.245 mm (0.0486-0.0490 in.)	1.265 mm (0.050 in.)
		Second (K20A6 engine)	1.220-1.230 mm (0.0481-0.0484 in.)	1.25 mm (0.049 in.)
		Second (K24A3 engine)	1.230-1.240 mm (0.0484-0.0488 in.)	1.26 mm (0.050 in.)
		Oil (K20A6 engine)	2.005-2.025 mm (0.0789-0.0797 in.)	2.05 mm (0.081 in.)
		Oil (K24A3 engine)	2.505-2.525 mm (0.0986-0.0994 in.)	2.55 mm (0.100 in.)
Piston ring	Ring-to-groove clearance	Top (K20A6 engine)	0.035-0.060 mm (0.0014-0.0024 in.)	0.13 mm (0.005 in.)
		Top (K24A3 engine)	0.045-0.070 mm (0.0018-0.0028 in.)	0.13 mm (0.005 in.)
		Second (K20A6 engine)	0.030-0.055 mm (0.0012-0.0022 in.)	0.13 mm (0.005 in.)
		Second (K24A3 engine)	0.040-0.065 mm (0.0016-0.0026 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 (K20A6 engine)	0.40-0.55 mm (0.016-0.022 in.)	0.70 mm (0.028 in.)
		Second (K24A3 engine)	0.50-0.65 mm (0.020-0.026 in.)	0.75 mm (0.030 in.)
		Oil (K20A6 engine)	0.25-0.65 mm (0.010-0.026 in.)	0.75 mm (0.030 in.)
		Oil (K24A3 engine)	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)	K20A6 engine	48.0 mm (1.89 in.)	———
		K24A3 engine	51.0 mm (2.01 in.)	———
	End play installed on crankshaft		0.15-0.35 mm (0.006-0.014 in.)	0.40 mm (0.016 in.)

Item	Measurement	Qualification	Standard or New	Service Limit
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	K20A6 engine	44.976-45.000 mm (1.7707-1.7717 in.)	———
		K24A3 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	K20A6 engine	0.020-0.050 mm (0.0008-0.0020 in.)	0.060 mm (0.0024 in.)
		K24A3 engine	0.032-0.066 mm (0.0013-0.0026 in.)	0.077 mm (0.0030 in.)

Engine Lubrication

Item	Measurement	Qualification	Standard or New	Service Limit
Engine oil	Capacity		5.3 [liter] (5.6 US qt, 4.7 lmp qt) for engine overhaul 4.2 [liter] (4.4 US qt, 3.7 lmp qt) for oil change, including filter 4.0 [liter] (4.2 US qt, 3.5 lmp qt) for oil change, without filter
Oil pump	Inner-to-outer rotor clearance	K20A6 engine	0.10-0.17 mm (0.004-0.007 in.)	0.20 mm (0.008 in.)
		K24A3 engine	0.06-0.16 mm (0.002-0.006 in.)	0.20 mm (0.008 in.)
	Pump housing-to-outer rotor clearance	K20A6 engine	0.035-0.090 mm (0.0014-0.0035 in.)	0.23 mm (0.009 in.)
		K24A3 engine	0.15-0.21 mm (0.006-0.008 in.)	0.23 mm (0.009 in.)
	Pump housing-to-rotor axial clearance	K20A6 engine	0.030-0.075 mm (0.0012-0.0030 in.)	0.12 mm (0.005 in.)
		K24A3 engine	0.020-0.055 mm (0.0008-0.0022 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 (K20A6 engine)	Front	0.060-0.140 mm (0.0024-0.0055 in.)	0.15 mm (0.006 in.)
		Rear	0.060-0.140 mm (0.0024-0.0055 in.)	0.15 mm (0.006 in.)
	Balancer shafts, end play (K24A3 engine)	Front	0.063-0.108 mm (0.0025-0.0043 in.)	0.14 mm (0.0055 in.)
		Rear	0.063-0.108 mm (0.0025-0.0043 in.)	0.14 mm (0.0055 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 °F)	At idle	70 kPa (0.7 kgf/cm2, 10 psi) min.
		at 3,000 rpm (min-1)	300 kPa (3.1 kgf/cm2, 44 psi) min.

Cooling

Item	Measurement	Qualification	Standard or New	Service Limit
Radiator	Coolant capacity for K20A6 engine (including engine, heater, hoses, and reservoir)	M/T: engine overhaul	6.6 [liter] (7.0 US qt, 5.8 Imp qt)
		M/T: coolant change	4.5 [liter] (4.8 US qt, 4.0 Imp qt)
		A/T: engine overhaul	6.5 [liter] (6.9 US qt, 5.7 lmp qt)
		A/T: coolant change	4.4 [liter] (4.6 US qt, 3.9 lmp qt)
	Coolant capacity for K24A3 engine (includes engine, heater, hoses, and reservoir)	M/T at engine overhaul	7.4 [liter] (7.8 US qt, 6.5 Imp qt)
		M/T at coolant change	5.4 [liter] (5.7 US qt, 4.8 Imp qt)
		A/T at engine overhaul	7.3 [liter] (7.7 US qt, 6.4 Imp qt)
		A/T at coolant change	5.3 [liter] (5.6 US qt, 4.7 Imp qt)
Reservoir	Coolant capacity		0.6 [liter] (0.6 US qt, 0.5 Imp qt)
Radiator cap	Opening pressure		93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)
Thermostat	Opening temperature	Begins to open	76-80°C (169-176°F)
		Fully open	90°C (194°F)
	Valve lift at fully open		8.0 mm (0.31 in.) min.
Radiator fan switch	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
Fuel pressure regulator	Pressure with regulator vacuum hose disconnected		333-383 kPa (3.4-3.9 kg/cm2, 48-55 psi)
Fuel tank	Capacity	Econo	62 [liter] (16.4 US gal, 13.6 Imp gal)
		Except Econo	65 [liter] (17.2 US gal, 14.3 Imp gal)
Engine idle	Idle speed without a load	Except K24A6 engine (MT) AT in [N] or [P], MT in neutral	650 ± 50 rpm (min-1)
		K24A6 engine in neutral (MT)	600 ± 50 rpm (min-1)
	Idle speed with mediom electric load (with headlights on)	AT in [N] or [P]	800 ± 50 rpm (min-1)
		MT in neutral	720 ± 50 rpm (min-1)
	Idle speed with high electric load (with headlights and HVAC on)	AT in [N] or [P]	800 ± 50 rpm (min-1)
		MT in neutral	720 ± 50 rpm (min-1)
	Idle CO %		0.1 max.

Clutch

Item	Measurement	Qualification	Standard or New	Service Limit
Clutch pedal	Height from floor		187 mm (7.36 in.)	———
	Stroke		130-140 mm (5.12-5.51 in.)	———
	Play		10-18 mm (0.39-0.71 in.)	———
	Disengagement height from floor		91 mm (3.58 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		1.2-1.7 mm (0.047-0.067 in.)	0.3 mm (0.01 in.)
	Thickness		8.2-8.9 mm (0.32-0.35 in.)	6.0 mm (0.24 in.)
Pressure plate	Warpage		0.08 mm (0.03 in.) max.	0.15 mm (0.006 in.)
	Height of diaphragm spring fingers measured with special tool and feeler gauge		0.6 mm (0.02 in.) max.	0.8 mm (0.03 in.)