|
Item
|
Engine
|
|
ZJ
|
ZY
|
Z6
|
|
Cylinder head
|
|
Cylinder head gasket contact surfaces distortion
|
(mm {in})
|
Maximum
|
0.10 {0.0039}
|
|
Manifold contact surfaces distortion
|
(mm {in})
|
Maximum
|
0.05 {0.002}
|
|
Maximum grinding
|
0.20 {0.008}
|
|
Valve clearance [Engine cold]
|
(mm {in})
|
IN
|
0.27-0.33 {0.0107-0.0129}
|
|
EX
|
|
Valve and valve guide
|
|
Valve head margin thickness
|
(mm {in})
|
Standard
|
IN
|
1.6-2.0 {0.063-0.078}
|
|
EX
|
|
Valve length
|
(mm {in})
|
Standard
|
IN
|
98.01-98.61
{3.859-3.882}
|
96.80-97.40 {3.812-3.834}
|
|
EX
|
98.44-99.04
{3.876-3.899}
|
96.30-96.90 {3.792-3.814}
|
|
Minimum
|
IN
|
97.79 {3.850}
|
96.58 {3.802}
|
|
EX
|
98.22 {3.867}
|
96.08 {3.783}
|
|
Valve stem diameter
|
(mm {in})
|
Standard
|
IN
|
5.470-5.485 {0.2154-0.2159}
|
|
EX
|
5.465-5.480 {0.2152-0.2157}
|
|
Minimum
|
IN
|
5.424 {0.2136}
|
|
EX
|
5.419 {0.2134}
|
|
Valve guide inner diameter
|
(mm {in})
|
Standard
|
IN
|
5.510-5.530 {0.2170-0.2177}
|
|
EX
|
|
Valve stem to guide clearance
|
(mm {in})
|
Standard
|
IN
|
0.025-0.060 {0.0010-0.0023}
|
|
EX
|
0.030-0.065 {0.0012-0.0025}
|
|
Maximum
|
IN
|
0.10 {0.04}
|
|
EX
|
|
Valve guide protrusion height
|
(mm {in})
|
IN
|
12.2-12.8 {0.49-0.50}
|
|
EX
|
|
Valve seat
|
|
Valve seat contact width
|
(mm {in})
|
Standard
|
IN
|
0.8-1.4 {0.032-0.055}
|
|
EX
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|
Valve seat angle
|
(°)
|
IN
|
45
|
|
EX
|
|
Valve seat sinking
(Valve protrusion height)
|
(mm {in})
|
Standard
|
IN
|
39.29 {1.5468}
|
|
EX
|
|
Valve spring
|
|
Pressing force at valve spring height H
|
(262.8 N {26.8 kgf,
59.0 lbf})
|
(mm {in})
|
27.5 {1.08}
|
|
Off-square
|
(° (mm {in}))
|
Maximum
|
2.0 (3.45 {0.136})
|
|
Tappet
|
|
Tappet bore diameter
|
(mm {in})
|
Standard
|
30.0-30.025 {1.1812-1.1820}
|
|
Tappet diameter
|
(mm {in})
|
Standard
|
29.959-29.975 {1.1795-1.1801}
|
|
Tappet-to-tappet bore oil clearance
|
(mm {in})
|
Standard
|
0.025-0.066 {0.0010-0.0025}
|
|
Maximum
|
0.180 {0.007}
|
|
Oil control valve (OCV)
|
|
Coil resistance [20° C{68°F}]
|
(ohm)
|
Standard
|
6.9-7.9
|
|
Camshaft
|
|
Camshaft runout
|
(mm {in})
|
Maximum
|
0.03 {0.001}
|
|
Cam lobe height
|
(mm {in})
|
Standard
|
IN
|
41.373 {1.6289}
|
|
EX
|
40.597 {1.5983}
|
41.495 {1.6337}
|
|
Minimum
|
IN
|
41.30 {1.6260}
|
|
EX
|
40.53 {1.5957}
|
41.43 {1.6311}
|
|
Journal diameter
|
(mm {in})
|
Standard
|
25.940-25.965 {1.0213-1.0222}
|
|
Minimum
|
24.910 {0.9807}
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|
Journal oil clearance
|
(mm {in})
|
Standard
|
0.035-0.081 {0.0014-0.0031}
|
|
Maximum
|
0.09 {0.0035}
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|
End play
|
(mm {in})
|
Standard
|
0.07-0.19 {0.0027-0.0074}
|
|
Maximum
|
0.20 {0.0078}
|
|
Cylinder block
|
|
Cylinder head gasket contact surfaces distortion
|
(mm {in})
|
Maximum
|
0.10 {0.0039}
|
|
Cylinder bore diameter
[Measure the cylinder bore at 35 mm {1.38 in} below the top surface]
|
(mm {in})
|
Maximum
|
74.0-74.013
{2.9134-2.9138}
|
78.0-78.013 {3.0709-3.0713}
|
|
Oil jet valve
|
|
Oil jet valve opening pressure
|
(kPa {kgf/cm2, psi})
|
230 {2.35, 33.4}
|
|
Piston
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|
Piston outer diameter
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(mm {in})
|
Standard
|
73.970-73.980
{2.9122-2.9125}
|
77.970-77.980 {3.0697-3.0700}
|
|
Piston-to-cylinder clearance
|
(mm {in})
|
Standard
|
0.020-0.043 {0.0008-0.0169}
|
|
Maximum
|
0.09 {0.0035}
|
|
Piston ring
|
|
Piston ring-to-ring groove clearance
|
(mm {in})
|
Standard
|
Top
|
0.035-0.065 {0.0014-0.0025}
|
|
Second
|
0.03-0.07 {0.0012-0.0027}
|
|
Oil (rail)
|
0.06-0.15 {0.0024-0.0059}
|
|
Maximum
|
Top
|
0.15 {0.0059}
|
|
Second
|
0.15 {0.0059}
|
|
Oil (rail)
|
0.20 {0.0078}
|
|
End gap
[measured in cylinder]
|
(mm {in})
|
Standard
|
Top
|
0.13-0.23
{0.006-0.009}
|
0.14-0.24 {0.006-0.009}
|
|
Second
|
0.23-0.38
{0.010-0.014}
|
0.24-0.39 {0.010-0.015}
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|
Oil (rail)
|
0.20-0.70 {0.008-0.027}
|
|
Maximum
|
Top
|
1.0 {0.039}
|
|
Second
|
1.0 {0.039}
|
|
Oil (rail)
|
1.0 {0.039}
|
|
Piston pin
|
|
Piston pin bore diameter
|
(mm {in})
|
Standard
|
17.988-18.000
{0.7082-0.7086}
|
18.988-19.000 {0.7476-0.7480}
|
|
Piston pin diameter
|
(mm {in})
|
Standard
|
17.974-17.980
{0.7077-0.7078}
|
18.974-18.980 {0.7471-0.7472}
|
|
Piston pin bore to piston pin clearance
|
(mm {in})
|
Standard
|
0.008-0.026 {0.0004-0.0010}
|
|
Connecting rod and connecting rod bearing
|
|
Connecting rod side clearance
|
(mm {in})
|
Standard
|
0.11-0.262 {0.0044-0.0103}
|
|
Maximum
|
0.435 {0.0171}
|
|
Connecting rod bearing size
|
(mm {in})
|
Standard
|
1.504-1.520
{0.0593-0.0598}
|
1.509-1.524 {0.0594-0.0599}
|
|
0.25 {0.01} Oversize
|
1.629-1.633
{0.0642-0.0643}
|
1.629-1.637 {0.0642-0.0644}
|
|
0.50 {0.02} Oversize
|
1.754-1.758
{0.0691-0.0692}
|
1.754-1.762 {0.0691-0.0693}
|
|
Connecting rod bearing oil clearance
|
(mm {in})
|
Standard
|
0.028-0.048
{0.0012-0.0018}
|
0.016-0.037 {0.0007-0.0014}
|
|
Maximum
|
0.10 {0.0039}
|
|
Connecting rod small end bore diameter
|
(mm {in})
|
Standard
|
17.943-17.961
{0.7065-0.7071}
|
18.943-18.961{0.7458-0.7464}
|
|
Connecting rod small end bore diameter to piston pin clearance
|
(mm {in})
|
Standard
|
-0.013- -0.037 {-0.0005- -0.0014}
|
|
Connecting rod bending
[Per 50mm {1.97in}]
|
(mm {in})
|
Maximum
|
0.050 {0.0019}
|
|
Connecting rod distortion [Per 50mm {1.97in}]
|
(mm {in})
|
Maximum
|
0.050 {0.0019}
|
0.075 {0.0029}
|
0.050{0.0019}
|
|
Connecting rod center-to-center distance
|
(mm {in})
|
Standard
|
140.05-140.15
{5.514-5.517}
|
140.60-140.70 {5.536-5.539}
|
135.15-135.25 {5.321-5.324}
|
|
Crankshaft
|
|
Thrust bearing size
|
(mm {in})
|
Standard
|
2.500-2.550 {0.0985-0.1003}
|
|
0.25 {0.01} Oversize
|
2.625-2.675 {0.1034-0.1053}
|
|
0.50 {0.02} Oversize
|
2.750-2.800 {0.1083-0.1102}
|
|
0.75 {0.03} Oversize
|
2.875-2.925 {0.1132-0.1151}
|
|
Crankshaft end play
|
(mm {in})
|
Standard
|
0.080-0.282 {0.0032-0.0111}
|
|
Maximum
|
0.30 {0.0118}
|
|
Crankshaft runout
|
(mm {in})
|
Maximum
|
0.10 {0.0039}
|
|
Main journal diameter
|
(mm {in})
|
Standard
|
49.938-49.956 {1.9661-1.9667}
|
|
0.25 {0.01} Oversize
|
49.688-49.706 {1.9562-1.9569}
|
|
0.50 {0.02} Oversize
|
49.438-49.456 {1.9463-1.9471}
|
|
Main journal off-round
|
(mm {in})
|
Maximum
|
0.05 {0.0019}
|
|
Crank pin journal diameter
|
(mm {in})
|
Standard
|
39.940-39.956
{1.5725-1.5730}
|
47.940-47.956 {1.8874-1.8880}
|
|
0.25 {0.01} Oversize
|
39.690-39.706
{1.5625-1.5632}
|
47.690-47.706 {1.8775-1.8782}
|
|
0.50 {0.02} Oversize
|
39.440-39.456
{1.5527-1.5533}
|
47.440-47.456 {1.8677-1.8683}
|
|
Crank pin off-round
|
(mm {in})
|
Maximum
|
0.10 {0.0039}
|
|
Main journal oil clearance
|
(mm {in})
|
Standard
|
0.014-0.038 {0.0006-0.0014}
|
|
Maximum
|
0.084 {0.0033}
|
|
Main bearing size
|
(mm {in})
|
Standard
|
2.511-2.529 {0.0989-0.0995}
|
|
0.25 {0.01} Oversize
|
2.625-2.635 {0.1034-0.1037}
|
|
0.50 {0.02} Oversize
|
2.750-2.760 {0.1083-0.1086}
|
|
Bolt
|
|
Cylinder head bolt length
|
(mm {in})
|
Standard
|
128.9-129.5 {5.075-5.098}
|
|
Maximum
|
130.2 {5.125}
|
|
Connecting rod bolt length
|
(mm {in})
|
Standard
|
36.2-36.6 {1.426-1.440}
|
46.7-47.3 {1.839-1.862}
|
|
Maximum
|
36.95 {1.454}
|
48.0 {1.889}
|
|
Oil pump
|
|
Inner rotor to outer rotor clearance
|
(mm {in})
|
Standard
|
0.02-0.18 {0.0008-0.0070}
|
|
Maximum
|
0.20 {0.0078}
|
|
Outer rotor to oil pump body clearance
|
(mm {in})
|
Standard
|
0.09-0.175 {0.0036-0.0068}
|
|
Maximum
|
0.20 {0.0078}
|
|
Side clearance
|
(mm {in})
|
Standard
|
0.03-0.07 {0.0012-0.0027}
|
|
Maximum
|
0.09 {0.0035}
|
|
Plunger spring free length
|
(mm {in})
|
Standard
|
45.94 {1.8087}
|
|
Front oil seal
|
|
Pushing distance of the front oil seal
[from the edge of the engine front cover]
|
(mm {in})
|
0-0.5 {0-0.019}
|
|
Rear oil seal
|
|
Pushing distance of the front oil seal
[from the edge of the cylinder block]
|
(mm {in})
|
0-0.5 {0-0.019}
|