EG1–77 ENGINE – ENGINE MECHANICAL SERVICE SPECIFICATIONS SERVICE DATA

Compression STD pressure Limit Difference between each cylinder Cylinder head Head surface warpage Limit Manifold surface warpage Limit seat Refacing angle Intake Exhaust Contacting angle Contacting width Valve guide Inner diameter Intake bushing Exhaust Outer diameter STD O/S 0.05 Replacing temperature (cylinder head side) Valve Valve overall length STD Intake Exhaust Valve face angle Stem diameter STD Intake Exhaust Stem end refacing Limit Stem oil clearance STD STD Intake Exhaust Limit Intake Exhaust Valve head edge thickness STD Limit Valve spring Free length Installed load at 40.5 mm (1.594 in.) STD Limit Squareness Limit Rocker arm Rocker arm inside diameter and shaft Rocker shaft diameter Shaft to arm oil clearance STD Limit Intake, surface warpage manifolds and Limit Intake air intake chamber Exhaust Air intake chamber

Chain and sprocket wear Limit sprocket Camshaft sprocket wear Limit EG1–78 ENGINE – ENGINE MECHANICAL

Tension and Tensioner head thickness Limit damper No. 1 damper wear Limit No. 2 damper wear Limit Camshaft Thrust clearance STD Limit Journal oil clearance STD Limit Journal diameter STD Circle runout Limit height STD Intake Exhaust Limit Intake Exhaust Cylinder block Cylinder head surface warpage Cylinder bore STD

Cylinder bore wear Limit Cylinder block main journal bore STD

Piston and Piston diameter STD piston ring

Piston to cylinder clearance Ring to ring groove clearance STD Limit Piston ring end gap STD

Limit

Piston pin installing temperature Connecting Thrust clearance STD rod Limit and bearing Bearing oil clearance STD Limit EG1–79 ENGINE – ENGINE MECHANICAL

Connecting Big end inner diameter rod and bearing (cont’d)

Connecting rod bearing center wall thickness

Pin to bushing oil clearance STD Limit Rod bend per 100 mm (3.94 in.) Limit Rod twist per 100 mm (3.94 in.) Limit Crankshaft Thrust clearance STD Limit Thrust washer thickness STD

Main journal oil clearance STD Limit Main journal diameter STD Main journal finished diameter

Main bearing center wall thickness STD

Crank pin diameter STD 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 EG1–80 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