ENGINE TECHNICAL DATA

id015000800100

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

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

25.950—25.975 {1.022—1.023}

Minimum

24.910 {0.9807}

Journal oil clearance

(mm {in})

Standard

0.034—0.080 {0.0014—0.0031}

Maximum

0.09 {0.0035}

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

Piston outer diameter

(mm {in})

Standard

73.970—74.004

{2.9122—2.9135}

77.970—78.004

{3.0697—3.0710}

77.970—77.980

{3.0697—3.0700}

Piston-to-cylinder clearance

(mm {in})

Standard

-0.004—0.043 {-0.0002—0.0169}

Maximum

0.065 {0.0026}

0.070 {0.0028}

0.090 {0.0035}

Piston ring

Piston ring-to-ring groove clearance

(mm {in})

Standard

Top

0.03—0.065 {0.0012—0.0025}

Second

0.03—0.07 {0.0012—0.0027}

Oil (rail)

0.04—0.15 {0.0016—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—0.50

{0.010—0.019}

0.24—0.39 {0.010—0.015}

Oil (rail)

0.10—0.70 {0.004—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}

Item					Engine
Item					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}
Manifold contact surfaces distortion	(mm {in})		Maximum grinding		0.20 {0.008}
Valve clearance [Engine cold]		(mm {in})		IN	0.27—0.33 {0.0107—0.0129}
Valve clearance [Engine cold]		(mm {in})		EX	0.27—0.33 {0.0107—0.0129}
Valve and valve guide
Valve head margin thickness	(mm {in})		Standard	IN	1.6—2.0 {0.063—0.078}
Valve head margin thickness	(mm {in})		Standard	EX	1.6—2.0 {0.063—0.078}
Valve length	(mm {in})		Standard	IN	98.01—98.61 {3.859—3.882}	96.80—97.40 {3.812—3.834}
			Standard	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}
			Minimum	EX	98.22 {3.867}	96.08 {3.783}
Valve stem diameter	(mm {in})		Standard	IN	5.470—5.485 {0.2154—0.2159}
			Standard	EX	5.465—5.480 {0.2152—0.2157}
			Minimum	IN	5.424 {0.2136}
			Minimum	EX	5.419 {0.2134}
Valve guide inner diameter	(mm {in})		Standard	IN	5.510—5.530 {0.2170—0.2177}
Valve guide inner diameter	(mm {in})		Standard	EX	5.510—5.530 {0.2170—0.2177}
Valve stem to guide clearance	(mm {in})		Standard	IN	0.025—0.060 {0.0010—0.0023}
			Standard	EX	0.030—0.065 {0.0012—0.0025}
			Maximum	IN	0.10 {0.04}
			Maximum	EX	0.10 {0.04}
Valve guide protrusion height	(mm {in})		IN		12.2—12.8 {0.49—0.50}
Valve guide protrusion height	(mm {in})		EX		12.2—12.8 {0.49—0.50}
Valve seat
Valve seat contact width	(mm {in})		Standard	IN	0.8—1.4 {0.032—0.055}
Valve seat contact width	(mm {in})		Standard	EX	0.8—1.4 {0.032—0.055}
Valve seat angle			(°)	IN	45
Valve seat angle			(°)	EX	45
Valve seat sinking (Valve protrusion height)	(mm {in})		Standard	IN	39.29 {1.5468}
Valve seat sinking (Valve protrusion height)	(mm {in})		Standard	EX	39.29 {1.5468}
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}
Tappet-to-tappet bore oil clearance	(mm {in})		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}
			Standard	EX	40.597 {1.5983}	41.495 {1.6337}
			Minimum	IN	41.30 {1.6260}
			Minimum	EX	40.53 {1.5957}	41.43 {1.6311}
Journal diameter	(mm {in})		Standard		25.950—25.975 {1.022—1.023}
Journal diameter	(mm {in})		Minimum		24.910 {0.9807}
Journal oil clearance	(mm {in})		Standard		0.034—0.080 {0.0014—0.0031}
Journal oil clearance	(mm {in})		Maximum		0.09 {0.0035}
End play	(mm {in})		Standard		0.07—0.19 {0.0027—0.0074}
End play	(mm {in})		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
Piston outer diameter	(mm {in})		Standard		73.970—74.004 {2.9122—2.9135}	77.970—78.004 {3.0697—3.0710}	77.970—77.980 {3.0697—3.0700}
Piston-to-cylinder clearance	(mm {in})		Standard		-0.004—0.043 {-0.0002—0.0169}
Piston-to-cylinder clearance	(mm {in})		Maximum		0.065 {0.0026}	0.070 {0.0028}	0.090 {0.0035}
Piston ring
Piston ring-to-ring groove clearance	(mm {in})		Standard	Top	0.03—0.065 {0.0012—0.0025}
				Second	0.03—0.07 {0.0012—0.0027}
				Oil (rail)	0.04—0.15 {0.0016—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—0.50 {0.010—0.019}	0.24—0.39 {0.010—0.015}
				Oil (rail)	0.10—0.70 {0.004—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}
Connecting rod side clearance	(mm {in})		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}
Connecting rod bearing oil clearance	(mm {in})		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}
Crankshaft end play	(mm {in})		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}
Main journal oil clearance	(mm {in})		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}
Cylinder head bolt length	(mm {in})		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}
Connecting rod bolt length	(mm {in})		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}
Inner rotor to outer rotor clearance	(mm {in})		Maximum		0.20 {0.0078}
Outer rotor to oil pump body clearance	(mm {in})		Standard		0.09—0.175 {0.0036—0.0068}
Outer rotor to oil pump body clearance	(mm {in})		Maximum		0.20 {0.0078}
Side clearance	(mm {in})		Standard		0.03—0.07 {0.0012—0.0027}
Side clearance	(mm {in})		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}