Engine Overhaul Specifications

All dimensions, diameters and gaps are in mm.

Z24 engines

Oil pressure:
At idle no less than	0.6 kgf/cm2
At 3000 rpm	2.8 - 4.0 kgf/cm2
Compression (at 350 rpm)
Standard	10.3 kgf/cm2
Limit	7.9 kgf/cm2
Rocker arms and camshaft	See Ch. 2A
Cylinder head
Deformation of split plane with cylinder block	0,1
Valves
Valve stem diameter
Intake	7,965 - 7.980
Graduation	7,945 - 7,960
Valve chamfer angle	45,50
Valve head edge width:
Intake
Standard	1,3
Limit	0.5
Graduation
Standard	1,5
Limit	0,5
Valve spring free height
Outer	49,77
Inner	44,0
Loaded:
Outer	springs
Standard	40,0 (under force 23k1s)
Limit	40,0 (under a force of 19 kgf)
Inner	springs
Standard	35,0 (11xGs)
Limit	35,0 (8.9 kgf)
Tolerance from vertical
Outer	2,2
Inner	1,9
Guide bush inner diameter	8,000-8,018
Gap between valve stem and guide bushing
Intake	0,020 - 0,053
Graduation	0,040 - 0,073
stem bend	no more than 0.2
Valve seat
Chamfer angle	45°
Collar width
Inlet valve seats	1,8-2,4
Exhaust valve seats	1,5-1,9
Valve length reduction due to trimming	0,20
Cylinder block
Deformation of the split plane under the head	no more than 0.1.
Cylinder inner diameter:
Group 1	89,000-89,010
Group 2	89,010-89,020
Group 3	89,020-89,030
Group 4	89,030- 89,040
Group 5	89,040 - 89,050
Taper and ovality	no more than 0.015
Piston-cylinder clearance	0,025-0,045
Pistons and rings
Piston diameter
on motors	Z24 1987
Standard	88,965- 88,975
1st repair	88,965- 88,975
2nd repair	89,465-89,515
3rd repair	89,965-90,015
On engines	Z24 1988
Group 1	88,965- 88,975
Group 2	88,975- 88,985
Group 3	88,985- 88,995
Group 4	88,995- 89,005
Group 5	89,005-89,015
Piston ring gap
For top compression	0,25-0,40
For lower compression	0,15-0,30
For mass removal	0,30-0,90
Gas between groove and piston ring
For top compression rings	0,040-0,073
For lower compression rings	0,030-0,063
Crankshaft, connecting rods and bearings
Connecting rod end play
Standard	0,2-0,3
Limit	0,6
Crankshaft end play
Standard	0,05-0,18
Limit	0,30
Main journal diameter	54,942-54,955
Crankpin diameter	49,961-49,974
Tapered and oval necks
Standard	0,01
Limit	0,03
Main bearing clearance
Standard	0,020- 0,062
Limit	0,12
Connecting rod bearing clearance:
Standard	0,025- 0,055
Limit	0,12
Flywheel runout no more than	0,15

Tightening torques (N·m) *

Main bearing cap bolts	43
Connecting rod bearing cap nuts	43

* See also Chap. 2, Part A

V6 engine

Oil pressure
Idling	not less than 0.55 kgf/cm2;
At 3200 rpm	3.2 - 4.0 kgf/cm2
Compression (at 350 rpm)
Standard	10.3 kgf/cm2
Limit	7.9 kgf/cm2
Compression difference between cylinders	no more than 0.8 kgf/cm2
Rocker arms and camshaft	See Ch. 2B
Cylinder head
Deformation of split plane with cylinder block	no more than 0.1
Head height	107+0,2
Valves
Valve bend	no more than 0.2 mm
Valve stem diameter
Intake	6,965 - 6,980
Graduation	7,965 - 7,970
Guide bushing inside diameter
Intake	7,000-7,018
Graduation	8,000-8,018
Gap between valve stem and guide bushing
Intake	0,020 - 0,053
Graduation	0,040 - 0,073
Limit	0.10 mm
Valve head edge width, max	0,5
Flap length
Intake	125,3-125,9
Graduation	124,2-124,8
Length reduction due to trimming	0,20
Valve spring free length
Inner	44,10
Outer	51,20
Loaded spring length
Inner	25,0 (26 kgf)
Outer	30,0 (53.4 kgf)
Tolerance from vertical
inner	1,9
Outer	2,2
Valve spring operating length
Inner	35,0
Outer	40,0
Valve seats
Chamfer angle	45°
Girdle width
Inlet valve seats	1,75
Exhaust valve seats	1,7
Cylinder block
Deformation of the split plane under the head	no more than 0.1.
Cylinder inner diameter:
Group 1	87,000-87,010
Group 2	87,010-87,020
Group 3	87,020 - 87,030
Group 4	87,030- 87,040
\Group 5	87,040 - 87,050
Diameter increase due to wear	no more than 0.20
Taper and ovality	no more than 0.015
Pistons and rings
Piston diameter (Ah, see the photo in the text)
Group 1	86,965- 86,975
Group 2	86,975- 86,985
Group 3	86,985- 86,995
Group 4	86,995- 87,005
Group 5	87,005-87,015
Piston to cylinder clearance
Before 1990	0,025- 0,045
Since 1991	0,015-0,035
The force of inserting a probe with a thickness of 0.04 mm between the piston and the cylinder is not more than	0.2-1.5 kgf
Groove to piston ring clearance
For top compression rings
Standard	0,040 - 0,073
Limit	0,1
For lower compression rings
Standard	0,030 - 0,063
Limit	0,1
For oil scraper rings	0,150-0,190
Piston ring gap
For top compression
Standard	0,21 - 0,44
Limit	1,0
For lower compression
Standard	0,18-0,44
Limit	1,0
For oil scrapers	0,20-0,76
Crankshaft, connecting rods and bearings
Connecting rod end play
Standard	0,2-0,35
Limit	0,4
Crankshaft end play
Standard	0,05-0,17
Limit	0,30
Main journal diameter
Group 0	62,967-62,975
Group 1	62,959-62,967
Group 2	62,951-62,959
Crankpin diameter	49,955-49,974
Tapered and oval necks	0,005
Main bearing clearance
Standard	0,028- 0,055
Limit	0,090
Connecting rod bearing clearance:
Standard	0,014-0,054
Limit	0,090
Main bearing diameter	identified by color coding
Group 0	black
Group 1	brown
Group 2	green
Group 3	yellow
Group 4	blue

Tightening torques (N·m) *

Main bearing cap bolts	80-98
Connecting rod bearing cap nuts
1st stage	12-14
2nd stage	28-33
Rear oil seal holder bolts	5-6

* See also Chap. 2, Part B

K24 engines

Oil pressure:
At idle no less than	0.6 kgf/cm2
At 3000 rpm	2.8 - 4.0 kgf/cm2
Compression (at 350 rpm)
Standard	11.6 kgf/cm2
Limit	8.7 kgf/cm2
Rocker arms and camshaft	See Ch. 2A
Cylinder head
Deformation of split plane with cylinder block	no more than 0.1
Valves
Valve stem diameter
Intake	6,965-6,980
Graduation	7,948 - 7,960
Valve chamfer angle	45,50
Valve head lip width:
Intake
Standard	1,15-1,45
Limit	0,5
Graduation
Standard	1,35-1,65
Limit	0,5
Valve spring free length
Intake valves
Outer	57,44
Inner	53,34
Exhaust valves
Outer	53,21
Inner	47,95
Spring working height
Intake valve outer springs
Standard		37,6 (under a force of 61.6 kgf)
Limit		37,6 (under a force of 57.9 kgf)
Inlet valve springs
Standard		32,6 (under a force of 29.0 kgf)
Limit		32,6 (under a force of 27.2 kgf) |
Exhaust valve outer springs
Standard		34,1 (under a force of 65.3 kgf)
Limit		34,1 (under a force of 63.3 kgf)
Internal exhaust valve springs
Standard		29,1 (under gain 33.5 kgf)
Limit		29,1 (under a force of 32.5 kgf)
Tolerance from vertical
Intake valves
Outer		2,5
Inner		2,3
Exhaust valves
Outer		2,3
Inner		2,1
Guide bushing inside diameter
Intake valves		7,000-7,018
Exhaust valves		8,000-8.018
Gap between valve stem and guide bushing
Intake		0,020-0,053
Graduation		0,040-0,070
Valve stem bend		no more than 0.2
Valve seat
Chamfer angle		45°
Ribbon width
Intake valve seats		1,6-1,7
Exhaust valve seats		1,7-2,1
Valve length reduction due to trimming		0,20
Cylinder block
Deformation of the split plane under the head		no more than 0.2
Cylinder inner diameter:
Group 1		89,000-89,010
Group 2		89,010-89,020
Group 3		89,020-89,030
Taper and ovality		no more than 0.015
Piston to cylinder clearance		0,020-0,040
Pistons and rings
Piston diameter		Standard
Group 1		88,970-88,980
Group 2		88,980-88,990
Group 3		88,990-89,000
1st repair		89,470-89,500
2nd repair		89,970-90,000
Piston ring gap
For top compression		0,28-0,52
For lower compression		0,45-0,69
For oil scrapers		0,20-0,69
Gas between groove and piston		ring
For top compression rings		0,040-0,080
For lower compression rings		0,030-0,070
For oil scrapers		0,065-0,135
Crankshaft, connecting rods and bearings
Connecting rod end play
Standard		0,2-0,4
Limit		0,6
Crankshaft end play
Standard		0,05-0,18
Limit		0,30
Main journal diameter
Group 1		63,645-63,652
Group 2		63,652-63,663
Group 3		63,663-63,672
Crankpin diameter		59,951-59,975
Tapered and oval necks
Pre-1990		no more than 0.01
Since 1991		0
Limit
Pre-1990		no more than 0.03
Since 1991		0,01
Main bearing clearance
Standard		0,020- 0,047
Limit		0,1
Connecting rod bearing clearance:
Standard		0,010-0,035
Limit		0,090
Flywheel runout		no more than 0.1

Tightening torques (H m) *

Main bearing cap bolts	43
Connecting rod bearing cap nuts
1st stage	12-14
2nd stage	35-40

* See also Chap. 2, Part A