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 | L13A5 (KY model) and L15A4 (IN model) engines | NGK: BKR5E-11 DENSO: K16PR-U11
Except L13A5 (KY model), L15A1, L15A4 (IN model) and L15A5 engines | NGK: BKR6E-11 DENSO: K20PR-U11
L15A5 (IN model) engine | NGK: ZFR6K-11 DENSO: KJ20DR-M11
L15A1 and L15A5 (FO model) engines | NGK: IZFR6K13 DENSO: SKJ20DR-M13
Gap | Except L15A1 and L15A5 (FO model) engines | 1.0-1.1 mm (0.039-0.043 in.) | ———
L15A1 and L15A5 (FO model) engines | 1.2-1.3 mm (0.047-0.051 in.) | 1.5 mm (0.059 in.)
Ignition timing | Except L15A1, L15A5 engines | At idle (check the red mark) | M/T (in neutral): 8±2° BTDC
CVT (in N or P position): 8±2° BTDC
L15A1, L15A5 engines | At idle (check the red mark) | M/T (in neutral): 12±2° BTDC
CVT (in N or P position): 8±2° BTDC
Drive belt NOTE: Adjust a new belt to the new belt spec., run the engine for 5 minutes, then readjust it to the used belt spec. | Deflection with 98 N (10 kgf, 22 Ibf) applied mid way between pulleys | Without A/C (with A/C, see ‘‘Compressor belt'' in the A/C table) | Used belt: 7.5-10.5 mm (0.30-0.41 in.)
New belt: 4.5-6.0 mm (0.18-0.24 in.)
Tension (measured with belt tension gauge) | Without A/C (with A/C, see ‘‘Compressor belt'' in the A/C table) | Used belt: 440-590 N (45-60 kgf, 99-130 Ibf)
New belt: 981-1,080 N (100-110 kgf, 220-243 Ibf)
Alternator | Output | At 13.5 V and normal engine temperature | 75A
Coil (rotor) resistance | At 20°C (68°F) | 2.6-2.9 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 mm (0.20 in.)
Brush spring tension |  | 3.3-4.1 N (0.34-0.42 kgf, 0.7-0.9 Ibf)

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Starter | Output | L12A1, L12A3, L13A1, L13A3, L13A4 and L13A5 engines for M/T model | 0.6 kW
L13A1, L13A3, L13A4 and L13A5 engines for CVT model | 0.7 kW
L15A1, L15A2, L15A4 and L15A5 engines | 0.7 kW
L13A2 engine | 1.0 kW
Commutator mica depth |  | 0.45-0.75 mm (0.018-0.030 in.) | 0.2 mm (0.008 in.)
Commutator runout |  | 0.05 mm (0.002 in.) max. | 0.4 mm (0.02 in.)
Commutator O.D. |  | 27.9-28.0 mm (1.098-1.102 in.) | 27.0 mm (1.06 in.)
Brush length |  | 9.7-10.3 mm (0.38-0.41 in.) | 6 mm (0.2 in.)

Engine Assembly
Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Compression | Pressure Check the engine with the starter cranking | Minimum | 980 kPa (10.0 kgf/cm2, 142 psi) | ———
Maximum variation | 200 kPa (2.0 kgf/cm2, 28 psi) | ———

Cylinder Head
Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Head | Warpage |  | ——— | 0.08 mm (0.003 in.)
Height |  | 119.9-120.1 mm (4.720-4.728 in.) | ———
Camshaft | End play |  | 0.05-0.25 mm (0.002-0.010 in.) | 0.5 mm (0.02 in.)
Camshaft-to-holder oil clearance |  | 0.045-0.084 mm (0.0018-0.0033 in.) | 0.100 mm (0.004 in.)
Total runout |  | 0.03 mm (0.001 in.) max. | 0.04 mm (0.002 in.)
Cam lobe height L12A1 and L12A3 engines | Intake | 35.471 mm (1.3965 in.) | ———
Exhaust | 35.444 mm (1.3954 in.) | ———
Cam lobe height L13A1, L13A2, L13A3, L13A4, L13A5, L15A2 and L15A4 engines | Intake | 35.471 mm (1.3965 in.) | ———
Exhaust | 35.558 mm (1.3999 in.) | ———
Cam lobe height L15A1 and L15A5 engines | Intake, primary | 35.3799 mm (1.39291 in.) | ———
Intake, secondary | 30.5291 mm (1.20193 in.) | ———
Exhaust | 35.3877 mm (1.39321 in.) | ———
Valve | Clearance (cold) | Intake | 0.15-0.19 mm (0.006-0.007 in.) | ———
Exhaust | 0.26-0.30 mm (0.010-0.012 in.) | ———
Stem O.D. | Intake | 5.48-5.49 mm (0.216-0.216 in.) | 5.45 mm (0.215 in.)
Exhaust | 5.45-5.46 mm (0.215-0.215 in.) | 5.42 mm (0.213 in.)
Stem-to-guide clearance | Intake | 0.020-0.050 mm (0.0008-0.0020 in.) | 0.08 mm (0.003 in.)
Exhaust | 0.050-0.080 mm (0.0020-0.0031 in.) | 0.11 mm (0.004 in.)
Valve seat | Width | Intake | 0.850-1.150 mm (0.0335-0.0453 in.) | 1.60 mm (0.063 in.)
Exhaust | 1.250-1.550 mm (0.0492-0.0610 in.) | 2.00 mm (0.079 in.)
Stem installed height | Intake | 46.1-46.5 mm (1.815-1.831 in.) | 46.8 mm (1.843 in.)
Exhaust | 46.2-46.6 mm (1.819-1.835 in.) | 46.9 mm (1.846 in.)
Valve spring | Free length | Intake | 50.52 mm (1.989 in.) | ———
Exhaust | 57.37 mm (2.259 in.) | ———
Valve guide | I.D. | Intake | 5.51-5.53 mm (0.217-0.218 in.) | 5.55 mm (0.219 in.)
Exhaust | 5.51-5.53 mm (0.217-0.218 in.) | 5.55 mm (0.219 in.)
Installed height | Intake | 15.85-16.35 mm (0.624-0.644 in.) | ———
Exhaust | 15.85-16.35 mm (0.624-0.644 in.) | ———
Rocker arm | Arm-to-shaft clearance | Intake | 0.019-0.058 mm (0.0007-0.0023 in.) | 0.08 mm (0.003 in.)
Exhaust | 0.019-0.058 mm (0.0007-0.0023 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 |  | 73.00-73.02 mm (2.8740-2.8748 in.) | 73.07 mm (2.8767 in.)
Bore taper |  | ——— | 0.05 mm (0.002 in.)
Reboring limit |  | ——— | 0.25 mm (0.01 in.)
Piston | Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt |  | 72.98-72.99 mm (2.8732-2.8736 in.) | 72.97 mm (2.8728 in.)
Clearance in cylinder |  | 0.010-0.040 mm (0.0004-0.0016 in.) | 0.05 mm (0.002 in.)
Ring groove width | Top | 1.050-1.060 mm (0.0413-0.0417 in.) | 1.08 mm (0.043 in.)
Second | 1.220-1.230 mm (0.0481-0.0484 in.) | 1.250 mm (0.0492 in.)
Oil | 2.005-2.020 mm (0.0789-0.0795 in.) | 2.050 mm (0.0807 in.)
Piston ring | Ring-to-groove clearance | Top | 0.065-0.090 mm (0.0026-0.0035 in.) | 0.15 mm (0.006 in.)
Second | 0.030-0.055 mm (0.0012-0.0022 in.) | 0.13 mm (0.005 in.)
Ring end gap | Top | 0.15-0.30 mm (0.006-0.012 in.) | 0.60 mm (0.024 in.)
Second | 0.35-0.50 mm (0.014-0.020 in.) | 0.65 mm (0.026 in.)
Oil | 0.20-0.70 mm (0.008-0.028 in.) | 0.80 mm (0.031 in.)
Piston pin | O.D. |  | 17.997-18.000 mm (0.7085-0.7087 in.) | ———
Pin-to-piston clearance |  | 0.010-0.017 mm (0.0004-0.0007 in.) | ———
Connecting rod | Pin-to-rod interference |  | 0.019-0.036 mm (0.0007-0.0014 in.) | ———
Small-end bore diameter |  | 17.964-17.977 mm (0.707-0.708 in.) | ———
Large-end bore diameter | Nominal | 43.0 mm (1.69 in.) | ———
End play installed on crankshaft |  | 0.15-0.30 mm (0.006-0.012 in.) | 0.40 mm (0.016 in.)
Crankshaft | Main journal diameter |  | 49.976-50.000 mm (1.9676-1.9685 in.) | ———
Rod journal diameter |  | 39.976-40.000 mm (1.5739-1.5748 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 bearing | Main bearing-to-journal oil clearance |  | 0.018-0.036 mm (0.0007-0.0014 in.) | 0.05 mm (0.0020 in.)
Rod bearing clearance |  | 0.020-0.038 mm (0.0008-0.0015 in.) | 0.05 mm (0.0020 in.)

Engine Lubrication
Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Engine oil | Capacity | Engine overhaul | 4.2 L (4.4 US qt, 3.7 Imp qt)
Oil change including oil filter | 3.6 L (3.8 US qt, 3.2 Imp qt)
Oil change without oil filter | 3.4 L (3.6 US qt, 3.0 Imp qt)
Oil pump | Inner rotor-to-outer rotor clearance |  | 0.02-0.14 mm (0.001-0.006 in.) | 0.20 mm (0.008 in.)
Pump housing-to-outer rotor clearance |  | 0.10-0.18 mm (0.004-0.007 in.) | 0.20 mm (0.008 in.)
Pump housing-to-rotor axial clearance |  | 0.02-0.07 mm (0.001-0.003 in.) | 0.15 mm (0.006 in.)
Relief valve | 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-1) | 340 kPa (3.5 kgf/cm2, 50 psi) min. | ———

Cooling
Item | Measurement | Qualification | Standard or New
--- | --- | --- | ---
With Heater | Without Heater
Radiator | Coolant capacity (Includes engine, heater, and reservoir) (Except L13A3 and L15A1 (KQ model) engines) (Aluminum radiator) | M/T: engine overhaul | 5.5 L (5.8 US qt, 4.8 Imp qt) | 4.9 L (5.1 US qt, 4.3 Imp qt)
M/T: coolant change | 3.9 L (4.1 US qt, 3.4 Imp qt) | 3.3 L (3.5 US qt, 2.9 Imp qt)
CVT: engine overhaul | 5.4 L (5.7 US qt, 4.7 Imp qt) | 4.8 L (5.0 US qt, 4.2 Imp qt)
CVT: coolant change | 3.8 L (4.0 US qt, 3.3 Imp qt) | 3.2 L (3.4 US qt, 2.8 Imp qt)
Coolant capacity (Includes engine, heater, and reservoir) (Except L13A3 and L15A1 (KQ model) engines) (Copper radiator) | M/T: engine overhaul | 5.6 L (5.9 US qt, 4.9 Imp qt) | 5.0 L (5.2 US qt, 4.3 Imp qt)
M/T: coolant change | 4.0 L (4.2 US qt, 3.5 Imp qt) | 3.4 L (3.6 US qt, 3.0 Imp qt)
CVT: engine overhaul | 5.5 L (5.8 US qt, 4.8 Imp qt) | 4.9 L (5.1 US qt, 4.3 Imp qt)
CVT: coolant change | 3.9 L (4.1 US qt, 3.4 Imp qt) | 3.3 L (3.5 US qt, 2.9 Imp qt)
Coolant capacity (Includes engine, heater, and reservoir) (L13A3 engine) (Aluminum radiator) | M/T: engine overhaul | 5.6 L (5.9 US qt, 4.9 Imp qt) | 5.0 L (5.2 US qt, 4.4 Imp qt)
M/T: coolant change | 4.0 L (4.2 US qt, 3.5 Imp qt) | 3.4 L (3.6 US qt, 3.0 Imp qt)
CVT: engine overhaul | 5.5 L (5.8 US qt, 4.6 Imp qt) | 4.9 L (5.1 US qt, 4.3 Imp qt)
CVT: coolant change | 3.9 L (4.1 US qt, 3.4 Imp qt) | 3.3 L (3.5 US qt, 2.9 Imp qt)
Coolant capacity (Includes engine, heater, and reservoir) (L13A3 engine) (Copper radiator) | M/T: engine overhaul | 5.7 L (6.0 US qt, 5.0 Imp qt) | 5.1 L (5.3 US qt, 4.4 Imp qt)
M/T: coolant change | 4.1 L (4.3 US qt, 3.6 Imp qt) | 3.5 L (3.7 US qt, 3.1 Imp qt)
CVT: engine overhaul | 5.6 L (5.9 US qt, 4.9 Imp qt) | 5.0 L (5.2 US qt, 4.4 Imp qt)
CVT: coolant change | 4.0 L (4.2 US qt, 3.5 Imp qt) | 3.4 L (3.6 US qt, 3.0 Imp qt)
Coolant capacity (Includes engine, heater, hoses, and reservoir) (L15A1 (KQ model) engine) | M/T: engine overhaul | 5.4 L (5.7 US qt, 4.7 Imp qt)
M/T: coolant change | 3.8 L (4.0 US qt, 3.3 Imp qt)
CVT: engine overhaul | 5.3 L (5.6 US qt, 4.7 Imp qt)
CVT: coolant change | 3.7 L (3.9 US qt, 3.3 Imp qt)
Reservoir | Coolant capacity |  | 0.4 L (0.4 US qt, 0.4 Imp qt)
Radiator cap | Opening pressure |  | 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)
Thermostat | Opening temperature (Except KN, KY, KZ, FO, IN and KP models) | Begins to open | 80-84°C (176-183°F)
Fully open | 95°C (203°F)
Opening temperature (KN, KY, KZ, FO, IN and KP models) | 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.
Thermoswitch | 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
--- | --- | --- | ---
Fuel pressure regulator | Pressure with fuel pressure gauge connected |  | 320-370 kPa (3.3-3.8 kgf/cm2, 47-54 psi)
Fuel tank | Capacity |  | 42 L (11 US gal, 9 Imp gal)
Engine idle | Idle speed without load (L12A1, L12A3 engines) | M/T in neutral | 700±50 rpm (min-1)
CVT in N or P position | 700±50 rpm (min-1)
Idle speed without load (L13A2, L13A3, L13A4, L13A5 engines and L13A1 engine for except 2005 KQ, KT, KK, and KB models) | M/T in neutral | 650±50 rpm (min-1)
CVT in N or P position | 750±50 rpm (min-1)
Idle speed without load (L13A1 engine for 2005 KQ, KT, KK, and KB models) | M/T in neutral | 600±50 rpm (min-1)
CVT in N or P position | 750±50 rpm (min-1)
Idle speed without load (L15A1, L15A2, L15A4, L15A5 engines) | M/T in neutral | 750±50 rpm (min-1)
CVT in N or P position | 750±50 rpm (min-1)
Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights at high beams ON) | M/T in neutral | 850±50 rpm (min-1)
CVT in N or P position | 850±50 rpm (min-1)
Idle CO |  | 0.1 % max.

Clutch
Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Clutch pedal | Height from floor | LHD model | 163 mm (6.42 in.) | ———
RHD model | 150 mm (5.91 in.) | ———
Stroke |  | 130-140 mm (5.12-5.51 in.) | ———
Play |  | 6-20 mm (0.2-0.8 in.) | ———
Disengagement height from the floor | LHD model | 72 mm (2.80 in.) min. | ———
RHD model | 61 mm (2.40 in.) | ———
Flywheel | Runout on clutch mating surface |  | 0.05 mm (0.002 in.) max. | 0.15 mm (0.006 in.)
Clutch disc | Rivet head depth |  | 1.1-1.6 mm (0.043-0.063 in.) | 0.2 mm (0.08 in.)
Thickness |  | 7.25-7.95 mm (0.29-0.31 in.) | 5.0 mm (0.20 in.)
Pressure plate | Warpage |  | 0.03 mm (0.001 in.) max. | 0.15 mm (0.006 in.)
Height of diaphragm spring fingers | Measure with feeler gauge and special tool | 0.8 mm (0.03 in.) max. | 1.0 mm (0.04 in.)