1AD-FTV ENGINE MECHANICAL SERVICE DATA

ENGINE
Engine speed Standard engine idle speed 750 to 850 rpm
Maximum engine speed 5100 to 5250 rpm
Compression Standard compression pressure

2500kPa (25.5 kgf/cm2, 362 psi) or higher

Minimum compression pressure

2200 kPa (22.5 kgf/cm2, 320 psi)

Difference between each cylinder

500 kPa (5.0 kgf/cm2, 71 psi) or less

CYLINDER HEAD GASKET
Piston protrusion Standard piston protrusion 0.300 to 0.560 mm (0.0118 to 0.0220 in.)
Cylinder head gasket New cylinder head gasket thickness Mark A 1.00 to 1.10 mm (0.0394 to 0.0433 in.)
Mark B 1.05 to 1.15 mm (0.0413 to 0.0453 in.)
Mark C 1.10 to 1.20 mm (0.0433 to 0.0472 in.)
Mark D 1.15 to 1.25 mm (0.0453 to 0.0492 in.)
Mark E 1.20 to 1.30 mm (0.0472 to 0.0512 in.)
Piston protrusion 0.300 to 0.355 mm (0.0118 to 0.0140 in.) Gasket use A
0.355 to 0.405 mm (0.0140 to 0.0159 in.) Gasket use B
0.405 to 0.455 mm (0.0159 to 0.0179 in.) Gasket use C
0.455 to 0.505 mm (0.0179 to 0.0199 in.) Gasket use D
0.505 to 0.560 mm (0.0199 to 0.0220 in.) Gasket use E
ENGINE UNIT
Chain sub-assembly Chain elongation Maximum 144.3 mm (5.68 in.)
Camshaft timing sprocket Sprocket with chain sub-assembly diameter Minimum 132.6 mm (5.22 in.)
Crankshaft timing sprocket Sprocket with chain sub-assembly diameter Minimum 69.1 mm (2.70 in.)
Chain tensioner slipper Wear Maximum 1.0 mm (0.0394 in.)
No. 1 chain vibration damper Wear Maximum 1.0 mm (0.0394 in.)
Intake manifold Warpage Maximum 0.10 mm (0.00394 in.)
Exhaust manifold Warpage Maximum 0.40 mm (0.0157 in.)
Camshaft Circle runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height Standard 37.559 to 37.759 mm (1.4787 to 1.4866 in.)
Minimum 37.559 mm (1.4787 in.)
Journal diameter Standard 26.969 to 26.985 mm (1.0618 to 1.0624 in.)
No. 2 camshaft Circle runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height Standard 38.270 to 38.470 mm (1.5067 to 1.5146 in.)
Minimum 38.270 mm (1.5067 in.)
Journal diameter Standard 26.969 to 26.985 mm (1.0618 to 1.0624 in.)
Camshaft clearance Oil clearance Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.062 mm (0.00244 in.)
Cylinder head set bolt Outside diameter Standard 11.8 to 12.0 mm (0.465 to 0.472 in.)
Minimum 11.2 mm (0.441 in.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Cylinder block side Maximum 0.05 mm (0.00197 in.)
Exhaust manifold side Maximum 0.05 mm (0.00197 in.)
Intake manifold side Maximum 0.05 mm (0.00197 in.)
Inner compression spring Free length Standard 45.9 mm (1.81 in.)
Deviation Maximum 1.5 mm (0.0591 in.)
Angle (Reference) Maximum
Intake valve Overall length Standard 104.4 mm (4.11 in.)
Minimum 104.1 mm (4.10 in.)
Valve stem diameter Standard 5.970 to 5.985 mm (0.23504 to 0.23563 in.)
Margin thickness Standard 1.40 to 1.60 mm (0.0551 to 0.0630 in.)
Minimum 0.50 mm (0.0197 in.)
Exhaust valve Overall length Standard 104.1 mm (4.10 in.)
Minimum 103.8 mm (4.09 in.)
Valve stem diameter Standard 5.960 to 5.975 mm (0.23464 to 0.23524 in.)
Margin thickness Standard 1.36 to 1.56 mm (0.0535 to 0.0614 in.)
Minimum 0.50 mm (0.0197 in.)
Camshaft clearance Thrust clearance Standard 0.035 to 0.160 mm (0.00138 to 0.00630 in.)
Maximum 0.160 mm (0.00630 in.)
Valve guide bush Bush inside diameter Standard 6.010 to 6.030 mm (0.23661 to 0.23740 in.)
Oil clearance Intake Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.06 mm (0.00236 in.)
Exhaust Standard 0.035 to 0.070 mm (0.00138 to 0.00276 in.)
Maximum 0.07 mm (0.00276 in.)
Bush bore diameter 10.985 to 11.006mm (0.432 to 0.433 in.) Use STD
11.035 to 11.056 mm (0.434 to 0.435 in.) Use O/S 0.05
Protrusion height Standard 9.0 to 9.4 mm (0.354 to 0.370 in.)
Intake valve seat Width Standard 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust valve seat Width Standard 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
CYLINDER BLOCK
Connecting rod Thrust clearance Standard 0.10 to 0.45 mm (0.00394 to 0.0177 in.)
Maximum 0.55 mm (0.0217 in.)
Oil clearance Standard 0.024 to 0.042 mm (0.000945 to 0.00165 in.)
Maximum 0.070 mm (0.00276 in.)
Cylinder block Warpage Maximum 0.05 mm (0.00197 in.)
Connecting rod big end Inside diameter Mark 1 Standard 53.000 to 53.006 mm (2.0866 to 2.0868 in.)
Mark 2 Standard 53.006 to 53.012 mm (2.0868 to 2.0871 in.)
Mark 3 Standard 53.012 to 53.018 mm (2.0871 to 2.0873 in.)
Cylinder bore Diameter Standard 86.000 to 86.013 mm (3.3858 to 3.3863 in.)
Maximum 86.213 mm (3.3942 in.)
Piston Diameter Standard 85.919 to 85.933 mm (3.3826 to 3.3832 in.)
Oil clearance Standard 0.067 to 0.094 mm (0.00264 to 0.00370 in.)
Piston ring Ring groove clearance No. 1 compression ring Standard 0.095 to 0.135 mm (0.00374 to 0.00531 in.)
No. 2 compression ring Standard 0.08 to 0.12 mm (0.00315 to 0.00472 in.)
Oil ring Standard 0.03 to 0.07 mm (0.00118 to 0.00276 in.)
End gap No. 1 compression ring Standard 0.22 to 0.32 mm (0.00866 to 0.0126 in.)
Maximum 0.92 mm (0.0362 in.)
No. 2 compression ring Standard 0.93 to 1.08 mm (0.0366 to 0.0425 in.)
Maximum 1.68 mm (0.0661 in.)
Oil ring Standard 0.1 to 0.40 mm (0.00394 to 0.0157 in.)
Maximum 1.00 mm (0.0394 in.)
Piston pin hole Inside diameter Mark A Standard 29.009 to 29.013 mm (1.1421 to 1.1422 in.)
Mark B Standard 29.013 to 29.017 mm (1.1422 to 1.1424 in.)
Mark C Standard 29.017 to 29.021 mm (1.1424 to 1.1426 in.)
Piston pin Diameter Mark A (White) Standard 29.000 to 29.004 mm (1.1417 to 1.1419 in.)
Mark B (Pink) Standard 29.004 to 29.008 mm (1.1419 to 1.1420 in.)
Mark C (Blue) Standard 29.008 to 29.012 mm (1.1420 to 1.1422 in.)
Connecting rod bush Inside diameter Mark A Standard 29.019 to 29.023 mm (1.1425 to 1.1426 in.)
Mark B Standard 29.023 to 29.027 mm (1.1426 to 1.1428 in.)
Mark C Standard 29.027 to 29.031 mm (1.1428 to 1.1430n.)
Piston pin

Oil clearance

(Piston)

Standard 0.005 to 0.013 mm (0.000197 to 0.000512 in.)
Maximum 0.05 mm (0.00197 in.)

Oil clearance

(Connecting rod)

Standard 0.15 to 0.23 mm (0.000591 to 0.000906 in.)
Maximum 0.025 mm (0.000984 in.)
Connecting rod alignment Bend Maximum 0.03 mm (0.00118 in.) per 100 mm (3.94 in.)
Twist Maximum 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Connecting rod bolt Diameter Standard 8.7 to 8.8 mm (0.343 to 0.346 in.)
Minimum 8.5 mm (0.335 in.)
Connecting rod bearing Center Wall Thickness Mark 1 Standard 1.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 2 Standard 1.488 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 3 Standard 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
Mark 4 Standard 1.494 to 1.497 mm (0.0588 to 0.0589 in.)
Mark 5 Standard 1.497 to 1.500 mm (0.0589 to 0.0591 in.)
Crankshaft thrust washer Thickness Standard 1.93 to 1.98 mm (0.0760 to 0.780 in.)
Crankshaft Thrust clearance Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Maximum 0.30 mm (0.0118 in.)
Pin diameter Mark 0 Standard 49.994 to 50.000 mm (1.9683 to 1.9685 in.)
Mark 1 Standard 49.988 to 49.994 mm (1.9680 to 1.9683 in.)
Mark 2 Standard 49.982 to 49.988 mm (1.9678 to 1.9680 in.)
Circle runout Maximum 0.04 mm (0.00157 in.)
Main journal Diameter Standard 58.982 to 59.000 mm (2.3221 to 2.3228 in.)
Taper and out-of-round Maximum 0.005 mm (0.000197 in.)
Crank pin Diameter Standard 49.982 to 50.000 mm (1.9678 to 1.9685 in.)
Taper and out-of-round Maximum 0.003 mm (0.000118 in.)
Oil clearance No. 3 journal Standard 0.020 to 0.038 mm (0.000787 to 0.00150 in.)
Maximum 0.10 mm (0.00394 in.)
Others Standard 0.014 to 0.032 mm (0.000551 to 0.00126 in.)
Maximum 0.10 mm (0.00394 in.)
Cylinder block main journal bore Diameter No. 3 journal Mark 0 Standard 63.000 to 63.006 mm (2.4803 to 2.4805 in.)
Mark 1 Standard 63.006 to 63.012 mm (2.4805 to 2.4808 in.)
Mark 2 Standard 63.012 to 63.018 mm (2.4808 to 2.4810 in.)
Others Mark 1 Standard 63.000 to 63.006 mm (2.4803 to 2.4805 in.)
Mark 2 Standard 63.006 to 63.012 mm (2.4805 to 2.4808 in.)
Mark 3 Standard 63.012 to 63.018 mm (2.4808 to 2.4810 in.)
Crankshaft main journal Diameter Mark 0 Standard 58.994 to 59.000 mm (2.3226 to 2.3228 in.)
Mark 1 Standard 58.988 to 58.994 mm (2.3224 to 2.3226 in.)
Mark 2 Standard 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
Crankshaft bearing Center wall thickness Mark 0 Standard 1.987 to 1.990 mm (0.0782 to 0.0783 in.)
Mark 1 Standard 1.990 to 1.993 mm (0.0783 to 0.0785 in.)
Mark 2 Standard 1.993 to 1.996 mm (0.0785 to 0.0786 in.)
Mark 3 Standard 1.996 to 1.999 mm (0.0786 to 0.0787 in.)
Mark 4 Standard 1.999 to 2.002 mm (0.0787 to 0.0788 in.)
Mark 5 Standard 2.002 to 2.005 mm (0.0788 to 0.0789 in.)
Crankshaft bearing cap bolt Diameter Standard 10.8 to 11.0 mm (0.425 to 0.433 in.)
Minimum 10.4 mm (0.409 in.)