1AD-FTV ENGINE MECHANICAL SERVICE DATA
ENGINE |
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Engine Speed |
Standard Engine Idle Speed |
720 to 820 rpm |
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Maximum Engine Speed |
5100 to 5250 rpm |
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Compression |
Standard Compression Pressure |
2500kPa (25.5 kgf/cm2, 362 psi) or higher |
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Minimum Compression Pressure |
2200 kPa (22.5 kgf/cm2, 320 psi) |
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Difference Between each Cylinder |
500 kPa (5.0 kgf/cm2, 71 psi) or less |
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CYLINDER HEAD GASKET |
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Piston Protrusion |
Standard Piston Protrusion |
0.300 to 0.560 mm (0.01181 to 0.0220 in.) |
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Cylinder Head Gasket |
New Cylinder Head Gasket Thickness |
Cutout Mark A |
1.00 to 1.10 mm (0.0394 to 0.0433 in.) |
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Cutout Mark B |
1.05 to 1.15 mm (0.0413 to 0.0453 in.) |
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Cutout Mark C |
1.10 to 1.20 mm (0.0433 to 0.0472 in.) |
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Cutout Mark D |
1.15 to 1.25 mm (0.0453 to 0.0492 in.) |
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Cutout Mark E |
1.20 to 1.30 mm (0.0472 to 0.0512 in.) |
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Piston Protrusion |
Gasket Size Use A |
0.300 to 0.355 mm (0.0118 to 0.0140 in.) |
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Gasket Size Use B |
0.355 to 0.405 mm (0.0140 to 0.0159 in.) |
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Gasket Size Use C |
0.405 to 0.455 mm (0.0159 to 0.0179 in.) |
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Gasket Size Use D |
0.455 to 0.505 mm (0.0179 to 0.0199 in.) |
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Gasket Size Use E |
0.505 to 0.560 mm (0.0199 to 0.0220 in.) |
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ENGINE UNIT |
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Chain Sub-assembly |
Maximum Chain Elongation |
144.3 mm (5.68 in.) |
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Camshaft Timing Sprocket |
Minimum Sprocket with Chain Sub-assembly Diameter |
132.6 mm (5.22 in.) |
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Crankshaft Timing Sprocket |
Minimum Sprocket with Chain Sub-assembly Diameter |
69.1 mm (2.70 in.) |
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Chain Tensioner Slipper |
Maximum Wear |
1.0 mm (0.0394 in.) |
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No. 1 Chain Vibration Damper |
Maximum Wear |
1.0 mm (0.0394 in.) |
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Intake Manifold |
Maximum Warpage |
0.10 mm (0.00394 in.) |
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Exhaust Manifold |
Maximum Warpage |
0.40 mm (0.0157 in.) |
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Camshaft |
Maximum Runout |
0.03 mm (0.00118 in.) |
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Standard Cam Lobe Height |
37.559 to 37.759 mm (1.4787 to 1.4866 in.) |
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Minimum Cam Lobe Height |
37.559 mm (1.4787 in.) |
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Standard Journal Diameter |
26.969 to 26.985 mm (1.0618 to 1.0624 in.) |
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No. 2 Camshaft |
Maximum Runout |
0.03 mm (0.00118 in.) |
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Standard Cam Lobe Height |
38.270 to 38.470 mm (1.5067 to 1.5146 in.) |
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Minimum Cam Lobe Height |
38.270 mm (1.5067 in.) |
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Standard Journal Diameter |
26.969 to 26.985 mm (1.0618 to 1.0624 in.) |
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Camshaft Clearance |
Standard Oil Clearance |
0.025 to 0.062 mm (0.000984 to 0.00244 in.) |
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Maximum Oil Clearance |
0.062 mm (0.00244 in.) |
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Standard Thrust Clearance |
0.035 to 0.160 mm (0.00138 to 0.00630 in.) |
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Maximum Thrust Clearance |
0.160 mm (0.00630 in.) |
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Cylinder Head Bolt |
Standard Outside Diameter |
11.8 to 12.0 mm (0.465 to 0.472 in.) |
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Minimum Outside Diameter |
11.2 mm (0.441 in.) |
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CYLINDER HEAD |
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Cylinder Head |
Maximum Warpage |
Cylinder Block Side |
0.05 mm (0.00197 in.) |
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Exhaust Manifold Side |
0.05 mm (0.00197 in.) |
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Intake Manifold Side |
0.05 mm (0.00197 in.) |
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Compression Spring |
Free Length |
45.9 mm (1.81 in.) |
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Maximum Deviation |
1.5 mm (0.0591 in.) |
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Maximum Angle (Reference) |
2° |
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Intake Valve |
Standard Overall Length |
104.4 mm (4.11 in.) |
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Minimum Overall Length |
104.1 mm (4.10 in.) |
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Valve Stem Diameter |
5.970 to 5.985 mm (0.23504 to 0.23563 in.) |
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Standard Margin Thickness |
1.40 to 1.60 mm (0.0551 to 0.0630 in.) |
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Minimum Margin Thickness |
0.50 mm (0.0197 in.) |
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Exhaust Valve |
Standard Overall Length |
104.1 mm (4.10 in.) |
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Minimum Overall Length |
103.8 mm (4.09 in.) |
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Valve Stem Diameter |
5.960 to 5.975 mm (0.23464 to 0.23524 in.) |
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Standard Margin Thickness |
1.36 to 1.56 mm (0.0535 to 0.0614 in.) |
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Minimum Margin Thickness |
0.50 mm (0.0197 in.) |
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Intake Valve Seat |
Standard Width |
1.0 to 1.4 mm (0.0394 to 0.0551 in.) |
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Exhaust Valve Seat |
Standard Width |
1.0 to 1.4 mm (0.0394 to 0.0551 in.) |
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Valve Guide Bush |
Bush Inside Diameter |
6.010 to 6.030 mm (0.23661 to 0.23740 in.) |
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Standard Oil Clearance |
Intake |
0.025 to 0.060 mm (0.00984 to 0.00236 in.) |
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Exhaust |
0.035 to 0.070 mm (0.00138 to 0.00276 in.) |
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Maximum Oil Clearance |
Intake |
0.06 mm (0.00236 in.) |
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Exhaust |
0.07 mm (0.00276 in.) |
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Bush Bore Diameter |
Use STD |
10.985 to 11.006mm (0.432 to 0.433in.) |
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Use O/S 0.05 |
11.035 to 11.056 mm (0.434 to 0.435 in.) |
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Standard Protrusion Height |
9.0 to 9.4 mm (0.354 to 0.370 in.) |
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CYLINDER BLOCK |
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Cylinder Block |
Maximum Warpage |
0.05 mm (0.00197 in.) |
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Cylinder Bore |
Standard Diameter |
86.000 to 86.013 mm (3.3858 to 3.3863 in.) |
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Maximum Diameter |
86.213 mm (3.3942 in.) |
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Piston |
Standard Piston Diameter |
85.919 to 85.933 mm (3.3826 to 3.3832 in.) |
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Standard Oil Clearance |
0.067 to 0.094 mm (0.00264 to 0.00370 in.) |
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Ring Groove Clearance |
No. 1 |
0.095 to 0.135 mm (0.00374 to 0.00531 in.) |
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No. 2 |
0.08 to 0.12 mm (0.00315 to 0.00472 in.) |
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Oil |
0.03 to 0.07 mm (0.00118 to 0.00276 in.) |
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Standard Piston Ring End Gap |
No. 1 |
0.22 to 0.32 mm (0.00866 to 0.0126 in.) |
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No. 2 |
0.93 to 1.08 mm (0.0366 to 0.0425 in.) |
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Oil |
0.1 to 0.40 mm (0.00394 to 0.0157 in.) |
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Maximum Piston Ring End Gap |
No. 1 |
0.92 mm (0.0362 in.) |
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No. 2 |
1.68 mm (0.0661 in.) |
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Oil |
1.00 mm (0.0394 in.) |
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Standard Piston Pin Hole Inside Diameter |
Mark A |
29.009 to 29.013 mm (1.1421 to 1.1422 in.) |
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Mark B |
29.013 to 29.017 mm (1.1422 to 1.1424 in.) |
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Mark C |
29.017 to 29.021 mm (1.1424 to 1.1426 in.) |
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Piston Pin Diameter |
Mark A (White) |
29.000 to 29.004 mm (1.1417 to 1.1419 in.) |
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Mark B (Pink) |
29.004 to 29.008 mm (1.1419 to 1.1420 in.) |
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Mark C (Blue) |
29.008 to 29.012 mm (1.1420 to 1.1422 in.) |
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Bush Inside Diameter |
Mark A |
29.019 to 29.023 mm (1.1425 to 1.1426 in.) |
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Mark B |
29.023 to 29.027 mm (1.1426 to 1.1428 in.) |
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Mark C |
29.027 to 29.031 mm (1.1428 to 1.1430n.) |
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Oil Clearance |
Standard Piston Pin Hole Oil Clearance |
0.005 to 0.013 mm (0.000197 to 0.000512 in.) |
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Maximum Piston Pin Hole Oil Clearance |
0.05 mm (0.00197 in.) |
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Standard Bush Inside Oil Clearance |
0.015 to 0.023 mm (0.000591 to 0.000906 in.) |
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Maximum Bush Inside Oil Clearance |
0.025 mm (0.000984 in.) |
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Connecting Rod Sub-assembly |
Maximum Bend |
0.03 mm (0.00118 in.) per 100 mm (3.94 in.) |
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Maximum Twist |
0.15 mm (0.00591 in.) per 100 mm (3.94 in.) |
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Standard Thrust Clearance |
0.10 to 0.45 mm (0.00394 to 0.0177 in.) |
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Maximum Thrust Clearance |
0.55 mm (0.0217 in.) |
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Standard Oil Clearance |
0.024 to 0.042 mm (0.000945 to 0.00165 in.) |
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Maximum Oil Clearance |
0.070 mm (0.00276 in.) |
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Connecting Rod Big End Inside Diameter |
Mark 1 |
53.000 to 53.006 mm (2.0866 to 2.0868 in.) |
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Mark 2 |
53.006 to 53.012 mm (2.0868 to 2.0871 in.) |
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Mark 3 |
53.012 to 53.018 mm (2.0871 to 2.0873 in.) |
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Connecting Rod Bolt |
Standard Diameter |
8.7 to 8.8 mm (0.343 to 0.346 in.) |
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Minimum Diameter |
8.5 mm (0.335 in.) |
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Crankshaft |
Pin Diameter |
Mark 0 |
49.994 to 50.000 mm (1.9683 to 1.9685 in.) |
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Mark 1 |
49.988 to 49.994 mm (1.9680 to 1.9683 in.) |
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Mark 2 |
49.982 to 49.988 mm (1.9678 to 1.9680 in.) |
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Standard Sized Bearing Center Wall Thickness |
Mark 1 |
1.485 to 1.488 mm (0.0585 to 0.0586 in.) |
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Mark 2 |
1.488 to 1.491 mm (0.0586 to 0.0587 in.) |
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Mark 3 |
1.491 to 1.494 mm (0.0587 to 0.0588 in.) |
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Mark 4 |
1.494 to 1.497 mm (0.0588 to 0.0589 in.) |
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Mark 5 |
1.497 to 1.500 mm (0.0589 to 0.0591 in.) |
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Maximum Runout |
0.04 mm (0.00157 in.) |
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Main Journal |
Standard Diameter |
Standard |
58.982 to 59.000 mm (2.3221 to 2.3228 in.) |
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Taper and Out-of-round |
Maximum |
0.005 mm (0.000197 in.) |
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Crank Pin |
Diameter |
Standard |
49.982 to 50.000 mm (1.9678 to 1.9685 in.) |
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Taper and Out-of-round |
Maximum |
0.003 mm (0.000118 in.) |
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Standard Thrust Clearance |
0.04 to 0.24 mm (0.00157 to 0.00945 in.) |
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Maximum Thrust Clearance |
0.30 mm (0.0118 in.) |
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Standard Thrust Washer Thickness |
1.93 to 1.98 mm (0.0760 to 0.0780 in.) |
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Standard Oil Clearance |
No. 3 |
0.020 to 0.038 mm (0.000787 to 0.00150 in.) |
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Others |
0.014 to 0.032 mm (0.000551 to 0.00126 in.) |
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Maximum Oil Clearance |
0.10 mm (0.00394 in.) |
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Standard Cylinder Block Main Journal Bore Diameter |
No. 3 Journal |
Mark 0 |
63.000 to 63.006 mm (2.4803 to 2.4805 in.) |
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Mark 1 |
63.006 to 63.012 mm (2.4805 to 2.4808 in.) |
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Mark 2 |
63.012 to 63.018 mm (2.4808 to 2.4810 in.) |
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Others |
Mark 1 |
63.000 to 63.006 mm (2.4803 to 2.4805 in.) |
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Mark 2 |
63.006 to 63.012 mm (2.4805 to 2.4808 in.) |
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Mark 3 |
63.012 to 63.018 mm (2.4808 to 2.4810 in.) |
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Crankshaft |
Standard Crankshaft Journal Diameter |
Mark 0 |
58.994 to 59.000 mm (2.3226 to 2.3228 in.) |
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Mark 1 |
58.988 to 58.994 mm (2.3224 to 2.3226 in.) |
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Mark 2 |
58.982 to 58.988 mm (2.3221 to 2.3224 in.) |
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Standard Sized Bearing Center Wall Thickness |
Mark 0 |
1.987 to 1.990 mm (0.0782 to 0.0783 in.) |
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Mark 1 |
1.990 to 1.993 mm (0.0783 to 0.0785 in.) |
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Mark 2 |
1.993 to 1.996 mm (0.0785 to 0.0786 in.) |
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Mark 3 |
1.996 to 1.999 mm (0.0786 to 0.0787 in.) |
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Mark 4 |
1.999 to 2.002 mm (0.0787 to 0.0788 in.) |
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Mark 5 |
2.002 to 2.005 mm (0.0788 to 0.0789 in.) |
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Crankshaft Bearing Cap Bolt |
Standard Diameter |
10.8 to 11.0 mm (0.425 to 0.433 in.) |
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Minimum Diameter |
10.4 mm (0.409 in.) |
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