Engine Electrical
Item Measurement Qualification Standard or New Service Limit 
Ignition coil Rated voltage  12 V 
Firing order  1-3-4-2 
Spark plug Type  NGK: ZFR6K-11
DENSO: KJ20DR-M11 
Gap  1.0-1.1 mm (0.039-0.043 in.) ——— 
Ignition timing  At idle (check the red mark) M/T (in neutral): 8±2° BTDC at 650±50 rpm (min-1
A/T (in [N] or [P]): 8±2° BTDC at 650±50 rpm (min-1
Alternator Output At 13.5 V and normal engine temperature 90 A 
Coil (rotor) resistance At 20 C° (68 F°) 1.84-2.10 W 
Slip ring O.D.  22.7 mm (0.89 in.) 21.7 mm (0.85 in.) 
Brush length  19.0 mm (0.75 in.) 5.0 mm (0.20 in.) 
Brush spring tension  3.3-4.1 N (0.34-0.42 kgf, 0.7-0.9 lbs) 
Starter
(MITSUBA) 
Output  1.2 kW, 1.6 kW 
Commutator mica depth  0.4-0.5 mm (0.016-0.020 in.) 0.15 mm (0.006 in.) 
Commutator runout  0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 
Commutator O.D.  28.0-28.1 mm (1.102-1.106 in.) 27.5 mm (1.083 in.) 
Brush length  11.1-11.5 mm (0.44-0.45 in.) 4.3 mm (0.17 in.) 
Starter
(DENSO) 
Output  1.0 kW, 1.1 kW 
Commutator mica depth  0.50-0.80 mm (0.020-0.031 in.) 0.2 mm (0.008 in.) 
Commutator runout  0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 
Commutator O.D.  28.0 mm (1.10 in.) 27.0 mm (1.06 in.) 
Brush length  14.0-14.5 mm (0.55-0.57 in.) 9.0 mm (0.35 in.) 
Brush spring tension  13.7-17.7 N (1.40-1.80 kgf, 3.09-3.98 lbs) 

Engine Assembly
Item Measurement Qualification Standard or New Service Limit 
Compression Pressure check at 250 (min-1) rpm with wide open throttle. (See Design Specs for ratio) Minimum 930 kPa (9.5 kgf/cm2, 135 psi) ——— 
Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) ——— 

Cylinder Head
Item Measurement Qualification Standard or New Service Limit 
Head Warpage  ——— 0.05 mm (0.002 in.) 
Height  103.95-104.05 mm
(4.093-4.096 in.) 
——— 
Camshaft End play  0.05-0.20 mm (0.002-0.008 in.) 0.4 mm (0.02 in.) 
Camshaft-to-holder oil clearance No.1 journal 0.030-0.069 mm
(0.001-0.003 in.) 
0.15 mm (0.006 in.) 
No.2, 3, 4, 5 journals 0.060-0.099 mm
(0.002-0.004 in.) 
0.15 mm (0.006 in.) 
Total runout  0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.) 
Cam lobe height Intake, primary 33.925 mm (1.3356 in.) ——— 
Intake, secondary 29.638 mm (1.1668 in.) ——— 
Exhaust 34.092 mm (1.3422 in.) ——— 
Valves Clearance (cold) Intake 0.21-0.25 mm (0.008-0.010 in.) ——— 
Exhaust 0.28-0.32 mm (0.011-0.013 in.) ——— 
Stem O.D. Intake 5.475-5.485 mm (0.2156-0.2159 in.) 5.445 mm (0.214 in.) 
Exhaust 5.450-5.460 mm (0.2146-0.2150 in.) 5.42 mm (0.213 in.) 
Stem-to-guide clearance Intake 0.030-0.055 mm (0.0012-0.0022 in.) 0.08 mm (0.003 in.) 
Exhaust 0.055-0.080 mm (0.0022-0.0031 in.) 0.11 mm (0.004 in.) 
Valve seats Width Intake 1.25-1.55 mm (0.049-0.061 in.) 2.00 mm (0.079 in.) 
Exhaust 1.25-1.55 mm (0.049-0.061 in.) 2.00 mm (0.079 in.) 
Stem installed height Intake 40.8-41.0 mm (1.606-1.614 in.) ——— 
Exhaust 54.6-54.8 mm (2.150-2.157 in.) ——— 
Valve springs Free length Intake 47.61 mm (1.874 in.) ——— 
Exhaust 49.64 mm (1.954 in.)
49.63 mm (1.954 in.) 
——— 
Valve guides I.D. Intake 5.515-5.530 mm
(0.2171-0.2177 in.) 
5.55 mm (0.219 in.) 
Exhaust 5.515-5.530 mm
(0.2171-0.2177 in.) 
5.55 mm (0.219 in.) 
Installed height Intake 15.2-16.2 mm (0.598-0.638 in.) ——— 
Exhaust 15.5-16.5 mm (0.610-0.650 in.) ——— 
Rocker arms Arm-to-shaft clearance Intake 0.025-0.052 mm
(0.0010-0.0020 in.) 
0.08 mm (0.003 in.) 
Exhaust 0.018-0.056 mm
(0.0007-0.0022 in.) 
0.08 mm (0.003 in.) 

Engine Block
Item Measurement Qualification Standard or New Service Limit 
Block Warpage of deck  0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.) 
Bore diameter
(K20A4, K20A5 engines) 
A or l 86.010-86.020 mm
(3.3862-3.3866 in.) 
86.070 mm (3.3886 in.) 
B or ll 86.000-86.010 mm
(3.3858-3.3862 in.) 
86.070 mm (3.3886 in.) 
Bore diameter
(K24A1 engines) 
A or l 87.010-87.020 mm
(3.4256-3.4260 in.) 
87.070 mm (3.4279 in.) 
B or lI 87.000-87.010 mm
(3.4252-3.4256 in.) 
87.070 mm (3.4279 in.) 
Bore taper  ——— 0.05 mm (0.002 in.) 
Reboring limit  ——— 0.25 mm (0.01 in.) 
Piston Skirt O.D. at 11 mm (0.4 in.) from bottom of skirt (K20A4, K20A5 engines) No letter or A 85.980-85.990 mm (3.3850-3.3854 in.) 85.930 mm (3.3831 in.) 
Letter B 85.970-85.980 mm (3.3846-3.3850 in.) 85.920 mm (3.3827 in.) 
Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt (K24A1 engine) No letter or A 86.980-86.990 mm (3.4244-3.4248 in.) 86.930 mm (3.4224 in.) 
Letter B 86.970-86.980 mm (3.4240-3.4244 in.) 86.920 mm (3.4220 in.) 
Clearance in cylinder  0.020-0.040 mm (0.0008-0.0016 in.) 0.05 mm (0.002 in.) 
Ring groove width Top (K20A4, K24A5 engines) 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in.) 
Top (K24A1 engine) 1.230-1.240 mm (0.0484-0.0488 in.) 1.26 mm (0.0450 in.) 
Second (K20A4, K20A5 engines) 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in.) 
Second (K24A1 engine) 1.240-1.250 mm (0.0488-0.0492 in.) 1.270 mm (0.050 in.) 
Oil (K20A4, K24A1 engines) 2.005-2.025 mm (0.0789-0.0797 in.) 2.05 mm (0.081 in.) 
Oil (K20A5 engine) 2.805-2.825 mm (0.1104-0.1112 in.) 2.85 mm (0.112 in.) 
Piston ring Ring-to-groove clearance Top (K20A4 engine) 0.035-0.060 mm (0.0014-0.0024 in.) 0.13 mm (0.005 in.) 
Top (K20A5 engine) 0.030-0.055 mm (0.0012-0.0022 in.) 0.13 mm (0.005 in.) 
Top (K24A1 engine) 0.045-0.070 mm (0.0018-0.0028 in.) 0.13 mm (0.005 in.) 
Second (K20A4, K20A5 engines) 0.030-0.055 mm (0.0012-0.0022 in.) 0.13 mm (0.005 in.) 
Second (K24A1 engine) 0.050-0.075 mm (0.0020-0.0030 in.) 0.13 mm (0.005 in.) 
Ring end gap Top 0.20-0.35 mm (0.008-0.014 in.) 0.60 mm (0.024 in.) 
Second 0.40-0.55 mm (0.016-0.022 in.) 0.70 mm (0.028 in.) 
Oil (K20A4 (Except KY models) engine) 0.25-0.65 mm (0.010-0.026 in.) 0.75 mm (0.030 in.) 
Oil (K20A4 (KY model), K20A5, K24A1 engines) 0.20-0.70 mm (0.008-0.028 in.) 0.80 mm (0.031 in.) 
Piston pin O.D.  21.961-21.965 mm (0.8646-0.8648 in.) 21.953 mm (0.8643 in.) 
Pin-to-piston clearance  -0.005-+0.002 mm (-0.00020-+0.00008 in.) 0.005 mm (0.0002 in.) 
Connecting rod Pin-to-rod clearance  0.005-0.015 mm (0.0002-0.0006 in.) 0.02 mm (0.0008 in.) 
Small-end bore diameter  21.970-21.976 mm (0.8650-0.8652 in.) ——— 
Large-end bore diameter (Normal) K20A4, K20A5 engines 48.0 mm (1.89 in.) ——— 
K24A1 engine 51.0 mm (2.01 in.) ——— 
End play installed on crankshaft  0.15-0.30 mm (0.006-0.012 in.) 0.40 mm (0.016 in.) 

Item Measurement Qualification Standard or New Service Limit 
Crankshaft Main journal diameter No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal 
54.984-55.008 mm (2.1648-2.1657 in.) ——— 
No. 3 journal 54.976-55.000 mm (2.1644-2.1654 in.) ——— 
Rod journal diameter K20A4, K20A5 engines 44.976-45.000 mm (1.7707-1.7717 in.) ——— 
K24A1 engine 47.976-48.000 mm (1.8888-1.8898 in.) ——— 
Rod/main journal taper  0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.) 
Rod/main journal out-of-round  0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.) 
End play  0.10-0.35 mm (0.004-0.014 in.) 0.45 mm (0.018 in.) 
Runout  0.03 mm (0.0012 in.) max. 0.04 mm (0.0016 in.) 
Crankshaft
bearings 
Main bearing-to-journal oil clearance No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal 
0.017-0.041 mm (0.0007-0.0016 in.) 0.050 mm (0.0020 in.) 
No. 3 journal 0.025-0.049 mm (0.0010-0.0019 in.) 0.055 mm (0.0022 in.) 
Rod bearing clearance  0.021-0.049 mm (0.0008-0.0019 in.) 0.060 mm (0.0024 in.) 

Engine Lubrication
Item Measurement Qualification Standard or New Service Limit 
Engine oil Capacity  5.3 L (5.6 US qt, 4.7 lmp qt) for engine overhaul
4.2 L (4.4 US qt, 3.7 lmp qt) for oil change, including filter
4.0 L (4.2 US qt, 3.5 lmp qt) for oil change, without filter 
Oil pump Inner-to-outer rotor clearance  0.02-0.16 mm (0.001-0.006 in.) 0.20 mm (0.008 in.) 
Pump housing-to-outer rotor clearance  0.15-0.21 mm (0.006-0.008 in.) 0.23 mm (0.009 in.) 
Pump housing-to-rotor axial clearance  0.02-0.07 mm (0.001-0.003 in.) 0.12 mm (0.005 in.) 
Balancer shafts, journal diameter No. 1 journal, front shaft 19.938-19.950 mm (0.7850-0.7854 in.) 19.92 mm (0.784 in.) 
No. 1 journal, rear shaft 23.938-23.950 mm (0.9424-0.9429 in.) 23.92 mm (0.942 in.) 
No. 2 journal, front and rear shaft 32.949-32.961 mm (1.2972-1.2977 in.) 32.93 mm (1.296 in.) 
Balancer shafts, journal taper  0.005 mm (0.0002 in.) max. ——— 
Balancer shafts, end play Front 0.070-0.135 mm (0.0028-0.0053 in.) 0.15 mm (0.006 in.) 
Rear 0.070-0.135 mm (0.0028-0.0053 in.) 0.15 mm (0.006 in.) 
Balancer shafts, shaft-to-bearing clearance No. 1 journal, front shaft 0.050-0.082 mm (0.0020-0.0032 in.) 0.10 mm (0.004 in.) 
No. 1 journal, rear shaft 0.050-0.082 mm (0.0020-0.0032 in.) 0.10 mm (0.004 in.) 
No. 2 journal, front and rear shaft 0.060-0.120 mm (0.0024-0.0047 in.) 0.15 mm (0.006 in.) 
Balancer shaft bearings, I.D. No. 1 journal, front shaft 20.000-20.020 mm (0.7874-0.7882 in.) 20.03 mm (0.789 in.) 
No. 1 journal, rear shaft 24.000-24.020 mm (0.9449-0.9457 in.) 24.03 mm (0.946 in.) 
No. 2 journal, front and rear shaft 33.021-33.069 mm (1.3000-1.3019 in.) 33.09 mm (1.303 in.) 
Relief valve, oil pressure with oil temperature at 80°C (176°F) At idle 70 kPa (0.7 kgf/cm2, 10 psi) min. 
At 3,000 rpm (min-1300 kPa (3.1 kgf/cm2, 44 psi) min. 

Cooling
Item Measurement Qualification Standard or New Service Limit 
Radiator Coolant capacity for K20A4 and K20A5 engines
(including engine, heater, hoses, and reservoir) 
M/T: engine overhaul 7.1 L (7.5 US qt, 6.2 Imp qt) 
M/T: coolant change 5.4 L (5.7 US qt, 4.8 Imp qt) 
A/T: engine overhaul 7.0 L (7.4 US qt, 6.2 lmp qt) 
A/T: coolant change 5.3 L (5.6 US qt, 4.7 lmp qt) 
Coolant capacity for K24A1 engine (includes engine, heater, hoses, and reservoir) M/T at engine overhaul 7.2 L (7.6 US qt, 6.3 Imp qt) 
M/T at coolant change 5.5 L (5.8 US qt, 4.8 Imp qt) 
A/T at engine overhaul 7.1 L (7.5 US qt, 6.2 Imp qt) 
A/T at coolant change 5.4 L (5.7 US qt, 4.8 Imp qt) 
Reservoir Coolant capacity  0.55 L (0.58 US qt, 0.48 Imp qt) 
Radiator cap Opening pressure  93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi) 
Thermostat Opening temperature Begins to open 76-80°C (169-176°F) 
Fully open 90°C (194°F) 
Valve lift at fully open  8.0 mm (0.31 in.) min. 
Radiator fan switch Switching temperature Turns ON 91-95°C (196-203°F) 
Turns OFF Subtract 3-8 °C (5-15 °F) from actual ON temperature 

Fuel and Emissions
Item Measurement Qualification Standard or New Service Limit 
Fuel pressure regulator Pressure with fuel pressure gauge connected  338-348 kPa (3.45-3.55 kgf/cm2, 49-50 psi)
 
Fuel tank Capacity  58 L (15 US gal, 13 Imp gal) 
Engine idle Idle speed without a load M/T in neutral 650±50 rpm (min-1
A/T in [N] or [P] position 650±50 rpm (min-1
Fast idle M/T in neutral 1,600±200 rpm (min-1
A/T in [N] or [P] position 1,600±200 rpm (min-1
Idle CO %  0.1 max. 

Clutch
Item Measurement Qualification Standard or New Service Limit 
Clutch pedal Height from floor  200 mm (7.87 in.) ——— 
Stroke  125-135 mm (4.92-5.31 in.) ——— 
Play  6-17 mm (0.24-0.67 in.) ——— 
Disengagement height from floor  112 mm (4.41 in.) min. ——— 
Flywheel Runout on clutch mating surface  0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.) 
Clutch disc Rivet head depth  1.65-2.25 mm (0.065-0.089 in.) 0.7 mm (0.03 in.) 
Thickness  8.7-9.3 mm (0.34-0.37 in.) 6.0 mm (0.24 in.) 
Pressure plate Warpage  0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.) 
Height of diaphragm spring fingers measured with special tool and feeler gauge  0.6 mm (0.02 in.) max. 0.8 mm (0.03 in.)