Grfe Engine Mechanical Service Data

Engine

Ignition timing

When using the intelligent tester

8 to 12° BTDC @ idle

When not using the

Connect SST

8 to 12° BTDC @ idle

intelligent tester

Disconnect SST

5 to 15° BTDC @ idle

Idle speed

When using the intelligent tester

600 to 700 rpm

When not using the intelligent tester

600 to 700 rpm

Compression

Compression pressure

1,400 kPa (14 kgf/cm2, 199 psi) or more

Minimum pressure

980 kPa (10.0 kgf/cm2, 142 psi)

Difference between each cylinder

100 kPa (1.0 kgf/cm2, 15 psi) or less

Intake manifold

Warpage

Maximum

Intake manifold side

0.8 mm (0.031 in.)

Cylinder head side

0.2 mm (0.008 in.)

Exhaust manifold

Warpage

Maximum

0.70 mm (0.0028 in.)

Connecting rod

Thrust clearance

Standard

0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum

0.50 mm (0.0197 in.)

Oil clearance

Standard

0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum

0.070 mm (0.0028 in.)

Big end inside diameter

Mark 1

56.000 to 56.006 mm (2.2047 to 2.2050 in.)

Mark 2

56.007 to 56.012 mm (2.2050 to 2.2052 in.)

Mark 3

56.013 to 56.018 mm (2.2052 to 2.2054 in.)

Mark 4

56.019 to 56.024 mm (2.2055 to 2.2057 in.)

Standard sized bearing center wall thickness

Mark 1

1.481 to 1.484 mm (0.0583 to 0.0584 in.)

Mark 2

1.484 to 1.497 mm (0.0584 to 0.0585 in.)

Mark 3

1.487 to 1.490 mm (0.0585 to 0.0587 in.)

Mark 4

1.490 to 1.493 mm (0.0587 to 0.0588 in.)

Bend

Maximum

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

Twist

Maximum

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

SS

Crankshaft

Pin diameter

Standard

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

Thrust clearance

Standard

0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum

0.30 mm (0.0118 in.)

Thrust washer thickness

Standard

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Main journal diameter

Standard

Mark 00

60.999 to 61.000 mm (2.4015 to 2.4016 in.)

Mark 01

60.998 to 60.999 mm (2.4015 to 2.4015 in.)

Mark 02

60.997 to 60.998 mm (2.4015 to 2.4015 in.)

Mark 03

60.996 to 60.997 mm (2.4014 to 2.4015 in.)

Mark 04

60.995 to 60.996 mm (2.4014 to 2.4014 in.)

Mark 05

60.994 to 60.995 mm (2.4013 to 2.4014 in.)

Mark 06

60.93 to 60.994 mm (2.4013 to 2.4013 in.)

Mark 07

60.992 to 60.993 mm (2.4013 to 2.4013 in.)

Mark 08

60.991 to 60.992 mm (2.4012 to 2.4013 in.)

Mark 09

60.990 to 60.991 mm (2.4012 to 2.4012 in.)

Mark 10

60.989 to 60.990 mm (2.4011 to 2.4012 in.)

Mark 11

60.988 to 60.989 mm (2.4.11 to 2.4011 in.)

Crankshaft

Upper bearing center wall thickness

Standard

No. 1 and No. 4 journal

Mark 1

2.500 to 2.503 mm (0.0984 to 0.0985 in.)

Mark 2

2.503 to 2.506 mm (0.0985 to 0.0987 in.)

Mark 3

2.506 to 2.509 mm (0.0987 to 0.0988 in.)

Mark 4

2.509 to 2.512 mm (0.0988 to 0.0989 in.)

Mark 5

2.512 to 2.515 mm (0.0989 to 0.0990 in.)

No. 2 and No. 3 journal

Mark 1

2.478 to 2.481 mm (0.0976 to 0.0977 in.)

Mark 2

2.481 to 2.484 mm (0.0977 to 0.0978 in.)

Mark 3

2.484 to 2.487 mm (0.0978 to 0.0979 in.)

Mark 4

2.487to 2.490 mm (0.0979 to 0.0980 in.)

Mark 5

2.490 to 2.493 mm (0.0980 to 0.0981 in.)

Crankshaft

Lower bearing center wall thickness

Standard

No. 1 and No. 4 journal

Mark 1

2.478 to 2.481 mm (0.0976 to 0.0977 in.)

Mark 2

2.481 to 2.484 mm (0.0977 to 0.0780 in.)

Mark 3

2.484 to 2.487 mm (0.0978 to 0.0979 in.)

Mark 4

2.487 to 2.490 mm (0.0979 to 0.0980 in.)

Mark 5

2.490 to 2.493 mm (0.0980 to 0.0981 in.)

No. 2 and No. 3 journal

Mark 1

2.500 to 2.503 mm (0.0984 to 0.0985 in.)

Mark 2

2.503 to 2.506 mm (0.0985 to 0.0987 in.)

Mark 3

2.506 to 2.509 mm (0.0987 to 0.0988 in.)

Mark 4

2.509 to 2.512 mm (0.0988 to 0.0989 in.)

Mark 5

2.512 to 2.515 mm (0.0989 to 0.0990 in.)

Circle runout

Maximum

0.06 mm (0.0024 in.)

Journal diameter

Standard

60.988 to 61.00 mm (2.4011 to 2.4016 in.)

Taper and out-of-round

Maximum

0.02 mm (0.0008 in.)

Crank pin diameter

Standard

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

Taper and out-of-round

Maximum

Taper and out-of-round0.02 mm (0.0008 in.)

Camshaft

Circle runout

Maximum

0.04 mm (0.0016 in.)

Cam lobe height

Standard

Intake

44.316 to 44.416 mm (1.7447 to 1.7487 in.)

Exhaust

44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Maximum

Intake

44.166 mm (1.7388 in.)

Exhaust

44.112 mm (1.7367 in.)

Journal diameter

Standard

No. 1 journal

35.946 to 35.960 mm (1.4152 to 1.4157 in.)

Other journal

25.959 to 25.975 mm (1.0220 to 1.0226 in.)

Thrust clearance (bank 1)

Standard

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

Maximum

0.15 mm (0.006 in.)

Thrust clearance (bank 2)

Standard

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

Maximum

0.15 mm (0.006 in.)

Oil clearance

Standard

No. 1 journal

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Other journal

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum

No. 1 Journal

0.10 mm (0.0039 in.)

Other journal

0.09 mm (0.0035 in.)

Timing chain

Chain elongation

Maximum

136.9 mm (5.389 in.)

No. 2 timing chain

Chain elongation

Maximum

137.6 mm (5.417 in.)

Crankshaft timing gear or sprocket

Sprocket diameter (w/ chain)

Minimum

61.4 mm (2.417 in.)

SS

Idle sprocket

Sprocket diameter (w/ chain)

Minimum

61.4 mm (2.417 in.)

Idle gear shaft

Idle gear shaft diameter

Standard

22.987 to 23.000 mm (0.9050 to 0.9055 in.)

Idle gear inside diameter

Standard

23.02 to 23.03 mm (0.9062 to 0.9067 in.)

Oil clearance

Standard

0.02 to 0.043 mm (0.0001 to 0.0017 in.)

Maximum

0.043 mm (0.0017 in.)

No. 2 chain tensioner

Depth

Maximum

0.9 mm (0.035 in.)

No. 3 chain tensioner

Depth

Maximum

0.9 mm (0.035 in.)

Chain tensioner slipper

Depth

Maximum

1.0 mm (0.039 in.)

No. 1 chain vibration damper

Depth

Maximum

1.0 mm (0.039 in.)

No. 2 chain vibration damper

Depth

Maximum

1.0 mm (0.039 in.)

Cylinder head

Warpage

Standard

Cylinder head lower side

0.05 mm (0.0020 in.)

Intake side

0.08 mm (0.0031 in.)

Exhaust side

0.08 mm (0.0031 in.)

Maximum

0.10 mm (0.0039 in.)

Protrusion height

Standard

18.0 to 19.0 mm (0.71 to 0.75 in.)

Intake valve guide bush

Cylinder bore diameter

Standard

10.285 to 10.306 mm (0.4049 to0.4057 in.)

Bush bore diameter

Standard

Use STD

10.335 to 10.356 mm (0.4069 to 0.4077 in.)

Use O/S

0.05 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Protrusion height

Standard

9.1 to 9.9 mm (0.3582 to 0.3900 in.)

Exhaust valve guide bush

Cylinder bore diameter

Standard

10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Bush bore diameter

Standard

Use STD

10.335 to 10.356 mm (0.4069 to 0.4077 in.)

Use O/S 0.05

10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Protrusion height

Standard

9.30 to 9.70 mm (0.3661 to 0.3819 in.)

Intake valve

Valve stem diameter

Standard

5.470 to 5.485 mm (0.2154 to 0.2159 in.)

Margin thickness

Standard

1.0 mm (0.0394 in.)

Minimum

0.50 mm (0.0197 in.)

Overall length

Standard

105.85 mm (4.1673 in.)

Minimum

105.35 mm (4.1476 in.)

Exhaust valve

Valve stem diameter

Standard

5.465 to 5.480 mm (0.2151 to 0.2157 in.)

Margin thickness

Standard

1.0 mm (0.0394 in.)

Minimum

0.50 mm (0.0197 in.)

Overall length

Standard

110.40 mm (4.3464 in.)

Minimum

109.90 mm (4.3268 in.)

Inner compression spring

Free length

Standard

45.46 mm (1.7898 in.)

Deviation

Maximum

1.0 mm (0.039 in.)

Angle (reference)

Maximum

Valve guide bush

Bush inside diameter

Standard

5.51 to 5.53 mm (0.2169 to 0.2177 in.)

Clearance

Standard

Intake

0.025 to 0.060 m (0.0010 to 0.0024 in.)

Exhaust

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Maximum

Intake

0.08 mm (0.0031 in.)

Exhaust

0.10 mm (0.0039 in.)

Cylinder block

Warpage

Maximum

0.07 mm (0.0028 in.)

Bore diameter

Standard

94.000 to 94.012 mm (3.7008 to 3.7013 in.)

Maximum

94.200 mm (3.7087 in.)

SS

Piston

Diameter

Standard

93.960 to 93.980 mm (3.6992 to 3.6999 in.)

Maximum

93.830 mm (3.6941 in.)

Distance

9.8 mm (0.3858 in.)

Oil clearance

Standard

0.020 to 0.052 mm (0.0007 to 0.0020 in.)

Maximum

0.06 mm (0.0024 in.)

Ring groove clearance

Standard

No. 1

0.020 to 0.070 mm (0.0008 to 0.0028 in.)

No. 2

0.020 to 0.060 mm (0.0008 to 0.0024 in.)

Oil

0.070 to 0.150 mm (0.0028 to 0.0059 in.)

Ring end gap

Standard

No. 1

0.25 to 0.35 mm (0.0098 to 0.0138 in.)

No. 2

0.50 to 0.60 mm (0.0197 to 0.0236 in.)

Oil

0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum

No. 1

0.50 mm (0.0197 in.)

No. 2

0.85 mm (0.0335 in.)

Oil

0.60 mm (0.0236 in.)

Piston pin hole inside diameter

Standard

Mark A

22.001 to 22.004 mm (0.8662 to 0.8663 in.)

Mark B

22.005 to 22.007 mm (0.8663 to 0.8664 in.)

Mark C

22.008 to 22.010 mm (0.8665 to 0.8665 in.)

piston pin diameter

Standard

Mark A

21.997 to 22.000 mm (0.8660 to 0.8661 in.)

Mark B

22.001 to 22.003 mm (0.8662 to 0.8663 in.)

Mark C

22.004 to 22.006 mm (0.8663 to 0.8664 in.)

Oil clearance

Standard

0.001 to 0.007 mm (0.00004 to 0.0003 in.)

Maximum

0.015 mm (0.0006 in.)

Bush inside diameter

Standard

Mark A

22.005 to 22.008 mm (0.8663 to 0.8665 in.)

Mark B

22.009 to 22.011 mm (0.8665 to 0.8666 in.)

Mark C

22.012 to 22.014 mm (0.8666 to 0.8667 in.)

Oil clearance

Standard

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum

0.03 mm (0.0012 in.)

Crankshaft bearing cap set bolt

Diameter

Standard

10.8 to 11.0 mm (0.4252 to 0.4331 in.)

Minimum

10.70 mm (0.4213 in.)

Cylinder head set bolt

Outside diameter

Minimum

10.70 mm (0.4213 in.)

Connecting rod bolt

Diameter

Standard

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum

7.0 mm (0.276 in.)

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