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1ND-TV ENGINE MECHANICAL(w/ DPF) SERVICE DATA

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Engine speed Idle 720 to 820 rpm
Maximum 5150 to 5250 rpm
Compression Standard

2300 kPa (23.5 kgf/cm2, 334 psi)

Minimum

2050 kPa (20.9 kgf/cm2, 297psi)

Difference between each cylinder

500 kPa (5.0 kgf/cm2, 71psi)

Valve clearance Clearance Standard Cold 0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust
Chain sub-assembly Length Maximum 156.5 mm (6.161 in.)
No. 2 chain sub-assembly Length Maximum 116.5 mm (4.586 in.)
Cylinder head sub-assembly Warpage Maximum Cylinder block side 0.08 mm (0.0032 in.)
Intake manifold side 0.02 mm (0.0079 in.)
Exhaust manifold 0.02 mm (0.0079 in.)
Camshaft oil clearance Clearance Standard 0.037 to 0.073 mm (0.0015 to 0.0029 in.)
Maximum 0.10 mm (0.0039 in.)
Camshaft thrust clearance Clearance Standard 0.080 to 0.180 mm (0.0032 to 0.0071 in.)
Maximum 0.25 mm (0.0098 in.)
Intake valve Overall length Standard 99.69 to 100.29 mm (3.9248 to 3.9484 in.)
Maximum 99.19 mm (3.9051 in.)
Exhaust valve Standard 99.39 to 99.99 mm (3.9130 to 3.9366 in.)
Maximum 98.89 mm (3.8933 in.)
Intake valve Diameter Standard 5.970 to 5.985 mm (0.2350 to 0.2356 in.)
Exhaust valve 5.965 to 5.980 mm (0.2348 to 0.2354 in.)
Intake valve Margin thickness Standard 1.2 mm (0.047 in.)
Minimum 0.6 mm (0.024 in.)
Standard 1.5 mm (0.059 in.)
Minimum 0.7 mm (0.028 in.)
Compression spring Length Standard 42.80 mm (1.6850 in.)
Deviation 1.5 mm (0.059 in.)
Cylinder head bolt Diameter Standard 11.5 to 12.0 mm (0.453 to 0.472 in.)
Minimum 11.2 mm (0.441 in.)
Valve guide bush Inside diameter Standard 6.010 to 6.030 mm (0.2366 to 0.2374 in.)
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.)
Minimum Intake 0.08 mm (0.0031in.)
Exhaust 0.10 mm (0.0039in.)
Bore diameter Standard 10.985 to 11.006 mm (0.4325 to 0.4333 in.)
Protrusion height Standard Intake 15.9 to 16.7 mm (0.626 to 0.657 in.)
Exhaust
Camshaft timing sprocket Diameter Minimum w/ chain 133.8 mm (5.268 in.)
Crankshaft timing sprocket 71.5 mm (2.815 in.)
Oil pump drive gear 56.4 mm (2.200 in.)
Oil pump drive shaft gear 58.6 mm (2.307 in.)
Tensioner slipper Wear Minimum 1.0 mm (0.039 in.)
No. 1 chain vibration damper Wear Minimum 1.0 mm (0.039 in.)
Chain tensioner plate Wear Minimum 1.0 mm (0.039 in.)
Camshaft Circle runout Maximum 0.03 mm (0.0012 in.)
Cam lobe height Standard Intake 34.484 to 34.584 mm (1.3576 to 1.3616 in.)
Exhaust 35.299 to 35.399 mm (1.3897 to 1.3937 in.)
Minium Intake 34.064 mm (1.3411 in.)
Exhaust 34.353 mm (1.3525 in.)
Journal diameter 23.979 to 23.995 mm (0.9441 to 0.9447 in.)
Connecting rod Thrust clearance Standard 0.16 to 0.36 mm (0.0063 to 0.0142 in.)
Maximum 0.36 mm (0.0142 in.)
Oil clearance Standard 0.014 to 0.038 mm (0.0006 to 0.0015 in.)
Maximum 0.065 mm (0.026 in.)
Thrust clearance Standard 0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Internal diameter Standard 27.022 to 27.034 mm (10.639 to 1.0634 in.)
Misalignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Twist 0.15 mm (0.006 in.) per 100 mm (3.94 in.)
Connecting rod Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Cylinder block Warpage Maximum 0.05 mm (0.0020 in.)
Cylinder bore Diameter Standard 73.000 to 73.013 mm (2.8740 to 2.8745 in.)
Maximum 73.133 mm (2.8792 in.)
Piston sub-assembly Diameter Standard 72.936 to 72.300 mm (2.8715 to 2.8740 in.)
Piston oil clearance Standard 0 to 0.047 mm (0 to 0.0019 in.)
Maximum 0.08 mm (0.0032 in.)
Piston pin hole Diameter Standard 27.019 to 27.031 mm (1.06374 to 1.06421 in.) at 20°C (68°F)
Piston pin Diameter Standard 27.008 to 27.020 mm (1.06331 to 1.06378 in.)
Piston ring Groove clearance Standard No. 1 0.110 to 0.150 mm (0.0043 to 0.0059 in.)
No. 2 0.070 to 0.110 mm (0.0028 to 0.0043 in.)
Oil ring 0.030 to 0.070 mm (0.0012 to 0.0028 in.)
End gap Standard No. 1 0.17 to 0.22 mm (0.0067 to 0.0087 in.)
No. 2 0.65 to 0.75 mm (0.0256 to 0.0295 in.)
Oil ring 0.10 to 0.30 mm (0.0039 to 0.0118 in.)
Maximum No. 1 0.42 mm (0.0165 in.)
No. 2 0.80 mm (0.0315 in.)
Oil ring 0.70 mm (0.0276 in.)
Connecting bolt Diameter Standard 6.6 to 6.7 mm (0.260 to 0.264 in.)
Minimum 6.4 mm (0.252 in.)
Crankshaft Circle runout Maximum 0.015 mm (0.0006 in.)
Diameter Standard Main journal 45.988 to 46.000 mm (1.8105 to 1.8100 in.)
Taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Diameter Standard Crank pin 43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Taper and out-of-round Maximum 0.02 mm (0.0008 in.)
Oil clearance Standard 0.010 to 0.023 mm (0.0004 to 0.0009 in.)
Maximum 0.07 mm (0.0028 in.)
Crankshaft bearing cap bolt Diameter Standard 10.8 to 11.0 mm (0.425 to 0.433 in.)
Minimum 10.6 mm (0.417 in.)