| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Ignition coil | Rated voltage | 12 V | ||
| Firing order | 1-3-4-2 | |||
| Spark plug | Type | K20A6 engine | ZFR6K-11 (NGK), KJ20DR-M11 (DENSO) | |
| K24A3 engine | IZFR6K11 (NGK), SKJ20DR-M11 (DENSO) | |||
| 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.) | ||
| 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) | ——— |
| 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.) |
| 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.) |
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Engine oil | Capacity | 5.3 [liter] (5.6 US qt, 4.7 Imp qt) for engine overhaul 4.2 [liter] (4.4 US qt, 3.7 Imp qt) for oil change, including filter 4.0 [liter] (4.2 US qt, 3.5 Imp 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. | |||
| 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 Imp qt) | |||
| A/T: coolant change | 4.4 [liter] (4.6 US qt, 3.9 Imp 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 | |||
| 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 | 65 [liter] (17.2 US gal, 14.3 Imp gal) | |
| Engine idle | Idle speed with no load | Except K24A3 engine (6MT) AT in [N] or [P], MT in neutral | 650 ± 50 rpm (min-1) |
| K24A3 engine (6MT) in neutral | 600 ± 50 rpm (min-1) | ||
| Idle CO % | 0.1 max. |
| 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.) |