1AD-FTV ENGINE MECHANICAL SERVICE DATA

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

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

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 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

2°

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.)

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.)