Service Data

Engine Mechanical Service Data (1 of 2)

New drive belt deflection
Pressing force: 98 N (10 kgf, 22lbf)	For fan and generator	7.0 to 8.5 mm (0.28 to 0.33 in.)
Pressing force: 98 N (10 kgf, 22lbf)	For vane pump	8.0 to 10.0 mm (0.31 to 0.39 in.)
Used drive belt deflection
Pressing force: 98 N (10 kgf, 22lbf)	For fan and generator	11.0 to 13.0 mm (0.43 to 0.51 in.)
Pressing force: 98 N (10 kgf, 22lbf)	For vane pump	11.0 to 13.0 mm (0.43 to 0.51 in.)
New drive belt tension
	For fan and generator	490 to 690 N (50 to 70 kgf, 110 to 155 Ib)
	For vane pump	445 to 667 N (45 to 68 kgf, 100 to 150 Ib)
Used drive belt tension
	For fan and generator	340 to 440 N (35 to 45 kgf, 76 to 99 Ib)
	For vane pump	267 to 445 N (27 to 45 kgf, 60 to 100 Ib)
Ignition timing		8 to 12 ° BTDC
Idle speed	M/T	650 ± 50 r/min
Idle speed	A/T	700 ± 50 r/min
Compression pressure		1,471 kPa (15.0 kgf/cm² 213 psi)
Minimum pressure		1,079 kPa (11.0 kgf/cm² 156 psi)
Difference between each cylinder		98 kPa (1 .Okgf/cm² 14 psi)
Valve clearance (cold)	Intake	0.15 to 0.25 mm (0.006 to 0.010 in.)
Valve clearance (cold)	Exhaust	0.25 to 0.35 mm (0.010 to 0.014 in.)
Chain elongation	Maximum	123.2 mm (4.850 in.)
Camshaft timing gear diameter (w/chain)	Minimum	96.2 mm (3.787 in.)
Camshaft timing sprocket diameter (w / chain)	Minimum	96.2 mm (3.787 in.)
Chain tensioner wear	Maximum	1.0 mm (0.039 in.)
Chain vibration wear	Maximum	1.0 mm (0.039 in.)
Cylinder head bolt length	Standard	142.8 to 144.2 mm (5.622 to 5.677 in.)
Cylinder head bolt length	Maximum	147.1 mm (5.791 in.)
Cylinder head warpage	Maximum Cylinder block side	0.05 mm (0.0020 in.)
	Intake manifold side	0.10 mm (0.0039 in.)
	Exhaust manifold side	0.10 mm (0.0039 in.)
Intake valve overall length	Standard	89.25 mm (3.5138 in.)
Intake valve overall length	Minimum	88.75 mm (3.4941 in.)
Intake valve stem diameter		4.970 to 4.985 mm (0.1957 to 0.1963 in.)
Intake valve margin thickness	Standard	1.0 mm (0.039 in.)
Intake valve margin thickness	Minimum	0.5 mm (0.020 in.)
Exhaust valve overall length	Standard	87.90 mm (3.4606 in.)
Exhaust valve overall length	Minimum	87.40 mm (3.4409 in.)
Exhaust valve stem diameter		4.965 to 4.980 mm (0.1955 to 0.1961 in.)
Exhaust valve margin thickness	Standard	1.15 mm (0.045 in.)
Exhaust valve margin thickness	Minimum	0.5 mm (0.020 in.)
Valve spring free length		45.1 mm (1.776 in.)
Valve spring deviation	Maximum	1.6 mm (0.063 in.)
Valve spring angle (reference)	Maximum	2°
Valve spring installed tension at 32.5 mm (1.280 in.)		149 to 165 N (15.2 to 16.8 kgf, 33.5 to 37.1 lbf)
Valve spring working tension at 23.9 mm (0.941 in.)	Maximum	286 to 316 N (29.1 to 32.2 kgf, 64.2 to 71.0 lbf)
Bushing inside diameter		5.010 to 5.030 mm (0.1972 to 0.1980 in.)
Valve guide bushing oil clearance	Standard Intake	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
	Exhaust	0.030 to 0.065 mm (0.0012 to 0.0026 in.)
	Maximum Intake	0.08 mm (0.0032 in.)
	Exhaust	0.10 mm (0.0039 in.)
Valve guide bush diameter	Standard	9.685 to 9.706 mm (0.3813 to 0.3821 in.)
Valve guide bush diameter	O/S	9.735 to 9.755 mm (0.3833 to 0.3841 in.)
Bushing Protrusion height		9.0 to 9.4 mm (0.354 to 0.370 in.)

Engine Mechanical Service Data (2 of 2)

Lifter diameter		30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Lifter bore diameter		31.000 to 31.025 mm (1.2205 to 1.2215 in.)
Oil clearance	Standard	0.024 to 0.059 mm (0.0009 to 0.0023 in.)
Oil clearance	Maximum	0.1 mm (0.0039 in.)
Camshaft circle runout	Maximum	0.03 mm (0.0012 in.)
Camshaft cam lobe height	Standard	44.617 to 44.717 mm (1.7566 to 1.7605 in.)
Camshaft cam lobe height	Minimum	43.16 mm (1.6992 in.)
Camshaft No. 1 journal diameter		34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Camshaft other journals diameter		22.949 to 22.965 mm (0.9035 to 0.9041 in.)
No. 2 camshaft circle runout	Maximum	0.03 mm (0.0012 in.)
No. 2 camshaft cam lobe height	Standard	44.666 to 44.766 mm (1.7585 to 1.7624 in.)
No. 2 camshaft cam lobe height	Minimum	44.52 mm (1.7528 in.)
No. 2 camshaft No. 1 journal diameter		34.449 to 34.465 mm (1.3563 to 1.3569 in.)
No. 2 camshaft other journals diameter		22.949 to 22.965 mm (0.9035 to 0.9041 in.)
Camshaft thrust clearance	Standard	0.040 to 0.095 mm (0.0016 to 0.0037 in.)
Camshaft thrust clearance	Maximum	0.11 mm (0.0043 in.)
Camshaft oil clearance	Standard	0.035 to 0.072 mm (0.0014 to 0.0028 in.)
Camshaft oil clearance	Maximum	0.08 mm (0.0031 in.)
Camshaft bearing cap setting ring pin protrusion height		8.5 to 9.5 mm (0.335 to 0.374 in.)
Union protrusion	Union A	29 mm (1.14 in.)
Union protrusion	Union B	44 mm (1.73 in.)
Connecting rod thrust clearance	Standard	0.16 to 0.36 mm (0.0063 to 0.0142 in.)
Connecting rod thrust clearance	Maximum	0.36 mm (0.0142 in.)
Connecting rod oil clearance	Standard	0.016 to 0.040 mm (0.0006 to 0.0016 in.)
Connecting rod oil clearance	Maximum	0.06 mm (0.0024 in.)
Crankshaft thrust clearance	Standard	0.09 to 0.19 mm (0.0035 to 0.0075 in.)
Crankshaft thrust clearance	Maximum	0.03 mm (0.0012 in.)
Cylinder block warpage	Maximum	0.05 mm (0.0020 in.)
Cylinder bore diameter	Standard	75.000 to 75.133 mm (2.9528 to 2.9580 in.)
Piston diameter		74.945 to 74.955 mm (2.9506 to 2.9510 in.)
Piston pin hole diameter at 20°C (68°F)		18.013 to 18.016mm (0.7092 to 0.7093 in.)
Piston pin diameter		18.001 to 18.004 mm (0.7087 to 0.7088 in.)
Oil clearance	Standard	0.009 to 0.015 mm (0.0004 to 0.0006 in.)
Oil clearance	Maximum	0.050 mm (0.0020 in.)
Piston clearance	Standard	0.045 to 0.068 mm (0.0018 to 0.0027 in.)
Piston clearance	Maximum	0.08 mm (0.0031 in.)
Connecting rod out-of alignment	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod twist	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Piston ring groove clearance	No. 1	0.03 to 0.07 mm (0.0012 to 0.0028 in.)
Piston ring groove clearance	No. 2	0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Piston ring end gap	Standard No. 1	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
	No. 2	0.35 to 0.50 mm (0.0138 to 0.0197 in.)
	Oil (Side rail)	0.10 to 0.35 mm (0.0039 to 0.0138 in.)
	Maximum No. 1	0.91 mm (0.0358 in.)
	No. 2	1.06 mm (0.0417 in.)
	Oil (Side rail)	0.82 mm (0.0323 in.)
Connecting rod bolt diameter	Standard	6.6 to 6.7 mm (0.260 to 0.264 in.)
Connecting rod bolt diameter	Maximum	6.4 mm (0.252 in.)
Crankshaft circle runout	Maximum	0.03 mm (0.0012 in.)
Main journal diameter		45.988 to 46.000 mm (1.8106 to 1.8110 in.)
Main journal taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crank pin diameter		39.992 to 40.000 mm (1.5745 to 1.5748 in.)
Crank pin taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crankshaft timing sprocket diameter (w/ chain)	Standard	51.72 mm (2.0362 in.)
Crankshaft timing sprocket diameter (w/ chain)	Maximum	50.5 mm (1.988 in.)
Crankshaft bearing cap set bolt diameter	Standard	7.3 to 7.5 mm (0.287 to 0.295 in.)
Crankshaft bearing cap set bolt diameter	Minimum	7.2 mm (0.283 in.)
Crankshaft oil clearance	Standard	0.01 to 0.023 mm (0.0004 to 0.0009 in.)
Crankshaft oil clearance	Maximum	0.07 mm (0.0028 in.)
Tight plug depth		0.2 to 1.2 mm (0.008 to 0.047 in.)
Cylinder head set straight pin protrusion		8.5 to 9.5 mm (0.335 to0.374 in.)
Straight pin protrusion	Pin A	3.5 to 4.5 mm (0.138 to 0.177 in.)
	Pin B	18.5 to 19.5 mm (0.728 to 0.768 in.)
	Pin C	8.5 to 9.5 mm (0.335 to0.374 in.)
	Pin D	11.5 to 12.5 mm (0.453 to 0.492 in.)