N04C-US ENGINE MECHANICAL SERVICE DATA

ENGINE
Engine speed Standard idle speed 600 to 700 rpm
Maximum speed 3300 to 3400 rpm
Compression Standard compression pressure

3200 kPa (32.6 kgf/cm2, 464 psi) or higher

Minimum pressure

2700 kPa (27.5 kgf/cm2, 392 psi)

Standard difference between each cylinder

290 kPa (3.0 kgf/cm2, 42 psi) or less

Diesel smoke Standard 10% or less
DRIVE BELT
Fan and generator V belt Standard deflection New belt 10.5 to 12.5 mm (0.413 to 0.492 in.)
Used belt 12 to 13 mm (0.472 to 0.512 in.)
No. 1 V (Cooler compressor to crankshaft pulley) belt Standard deflection New belt 7 to 9 mm (0.276 to 0.354 in.)
Used belt 8.5 to 10 mm (0.335 to 0.394 in.)
VALVE CLEARANCE
Intake valve Standard (Cold) 0.25 to 0.40 mm (0.00984 to 0.0157 in.)
Exhaust valve Standard (Cold) 0.40 to 0.55 mm (0.0157 to 0.0217 in.)
CYLINDER HEAD
Cylinder head Warpage Maximum 0.10 mm (0.00394 in.)
Inner compression spring Deviation Maximum 2.0 mm (0.0787 in.)
Free length Standard 85.1 mm (3.350 in.)
Minimum 82.1 mm (3.232 in.)
Intake valve Overall length Standard 129.8 mm (5.1102 in.)
Valve stem diameter Standard 6.957 to 6.972 mm (0.2739 to 0.2745 in.)
Valve sink Standard 0.8 to 1.0 mm (0.0315 to 0.0394 in.)
Maximum 1.1 mm (0.0433 in.)
Exhaust valve Overall length Standard 128.8 mm (5.0709 in.)
Valve stem diameter Standard 6.932 to 6.947 mm (0.2729 to 0.2735 in.)
Valve sink Standard 1.8 to 2.0 mm (0.0709 to 0.0787 in.)
Maximum 2.1 mm (0.0827 in.)
Valve guide bush Bush inside diameter Standard 7.000 to 7.015 mm (0.2756 to 0.2762 in.)
Oil clearance Standard Intake 0.028 to 0.058 mm (0.00110 to 0.00228 in.)
Exhaust 0.053 to 0.083 mm (0.00209 to 0.00327 in.)
Maximum Intake 0.12 mm (0.00472 in.)
Exhaust 0.15 mm (0.00591 in.)
Intake valve seat Width Standard 1.24 mm (0.0488 in.) or more
Cylinder head dimension Standard A 36.000 to 36.015 mm (1.4173 to 1.4179 in.)
B 8.4 to 8.6 mm (0.3307 to 0.3386 in.)
Exhaust valve seat Width Standard 1.24 mm (0.0488 in.) or more
Cylinder head dimension Standard A 32.000 to 32.015 mm (1.2598 to 1.2605 in.)
B 7.6 to 7.8 mm (0.2992 to 0.3071 in.)
Intake valve guide bush Bush bore diameter Standard 13.000 to 13.018 mm (0.5118 to 0.5125 in.)
Protrusion height Standard 26.4 to 26.8 mm (1.039 to 1.055 in.)
Oil clearance Standard 0.028 to 0.058 mm (0.00110 to 0.00228 in.)
Maximum 0.120 mm (0.00472 in.)
Exhaust valve guide bush Bush bore diameter Standard 13.000 to 13.018 mm (0.5118 to 0.5125 in.)
Protrusion height Standard 26.4 to 26.8 mm (1.039 to 1.055 in.)
Oil clearance Standard 0.053 to 0.083 mm (0.00209 to 0.00327 in.)
Maximum 0.150 mm (0.00591 in.)
Injection nozzle seat Protrusion Standard 2.4 to 2.8 mm (0.0945 to 0.110 in.)
CYLINDER BLOCK
Connecting rod bolt Length Standard 58.8 to 59.0 mm (2.315 to 2.328 in.)
Maximum 61.5 mm (2.421 in.)
Cylinder liner Outside diameter Standard Symbol A 106.982 to 106.989 mm (4.2119 to 4.2122 in.)
Symbol B 106.990 to 106.995 mm (4.2122 to 4.2124 in.)
Symbol C 106.996 to 107.004 mm (4.2124 to 4.2128 in.)
Protrusion Standard 0.01 to 0.08 mm (0.000394 to 0.00315 in.)
Maximum 0.08 mm (0.00315 in.)
Cylinder bore Inside diameter Reference value (New parts) 104.012 to 104.036 mm (4.095 to 4.096 in.)
Maximum 104.15 mm (4.1004 in.)
Cylinder block Warpage Standard 0.10 mm (0.00394 in.)
Inside diameter Standard Symbol A 107.000 to 107.008 mm (4.2126 to 4.2129 in.)
Symbol B 107.008 to 107.014 mm (4.2129 to 4.2131 in.)
Symbol C 107.014 to 107.022 mm (4.2131 to 4.2135 in.)
Piston Diameter Reference value (New parts) 103.936 to 103.952 mm (4.0920 to 4.0926 in.)
Oil clearance Reference value 0.06 to 0.10 mm (0.00236 to 0.00394 in.)
Piston pin Diameter Standard 36.989 to 37.000 mm (1.4563 to 1.4567 in.)
Minimum 36.960 mm (1.4551 in.)
Bush inside diameter Standard 37.035 to 37.045 mm (1.4581 to 1.4585 in.)
Maximum 37.10 mm (1.4606 in.)

Oil clearance

(Connecting rod)

Standard 0.035 to 0.056 mm (0.00138 to 0.00220 in.)
Maximum 0.080 mm (0.00315 in.)
Piston pin hole inside diameter Standard 36.987 to 37.003 mm (1.4562 to 1.4568 in.)
Maximum 37.05 mm (1.4587 in.)

Oil clearance

(Piston)

Standard -0.013 to 0.14 mm (-0.000512 to 0.000551 in.)
Maximum 0.05 mm (0.00197 in.)
Piston ring Groove clearance Standard 1st 0.11 to 0.15 mm (0.00433 to 0.00591 in.)
2nd 0.07 to 0.11 mm (0.00276 to 0.00433 in.)
Oil 0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Maximum 0.30 mm (0.0118 in.)
Groove width Standard 1st 2.58 to 2.60 mm (0.1016 to 0.1024 in.)
2nd 2.06 to 2.08 mm (0.0811 to 0.0819 in.)
Oil 4.01 to 4.03 mm (0.1579 to 0.1587 in.)
Maximum 1st 3.10 mm (0.122 in.)
2nd 2.20 mm (0.0866 in.)
Oil 4.08 mm (0.1606 in.)
Ring Thickness Standard 1st 2.47 to 2.49 mm (0.0972 to 0.0980 in.)
2nd 1.97 to 1.99 mm (0.0776 to 0.0783 in.)
Oil 4.97 to 4.99 mm (0.1957 to 0.1965 in.)
Minimum 1st 2.32 mm (0.0913 in.)
2nd 1.82 mm (0.0717 in.)
Oil 4.95 mm (0.1949 in.)
End gap Standard 1st 0.30 to 0.45 mm (0.0118 in.)
2nd 0.50 to 0.65 mm (0.0197 to 0.0256 in.)
Oil 0.15 to 0.30 mm (0.00591 to 0.0118 in.)
Maximum 1st 1.2 mm (0.472 in.)
2nd 1.2 mm (0.472 in.)
Oil 1.2 mm (0.472 in.)
Crankshaft Thrust clearance Standard 0.050 to 0.220 mm (0.00197 to 0.00866 in.)
Maximum 0.40 mm (0.0157 in.)
Thrust washer thickness Standard 2.430 to 2.480 mm (0.0957 to 0.0976 in.)
Circle runout Maximum 0.04 mm (0.00157 in.)
Journal diameter Standard 72.94 to 72.96 mm (2.8717 to 2.8724 in.)
Minimum 71.76 mm (2.8252 in.)

Taper and distortion

(each main journal)

Maximum 0.01 mm (0.000394 in.)
Crankshaft pin diameter Standard 61.94 to 61.96 mm (2.4386 to 2.4394 in.)
Minimum 60.76 mm (2.3921 in.)

Taper and distortion

(each crankshaft pin)

Maximum 0.01 mm (0.000394 in.)
Journal width Standard 34.00 to 34.08 mm (1.339 to 1.342 in.)
Maximum 34.48 mm (1.357 in.)
Crankshaft bearing cap inside diameter Standard 77.985 to 78.000 mm (3.0703 to 3.0709 in.)
Maximum 78.200 mm (3.0787 in.)
Crankshaft bearing inside diameter Standard 73.01 to 73.04 mm (2.8744 to 2.8756 in.)
Maximum 73.30 mm (2.8858 in.)
Oil clearance Standard 0.051 to 0.102 mm (0.00201 to 0.00402 in.)
Maximum 0.200 mm (0.00787 in.)
Bearing diameter STD 72.94 to 72.96 mm (2.8717 to 2.8724 in.)
U/S 0.25 72.69 to 72.71 mm (2.8618 to 2.8626 in.)
U/S 0.50 72.44 to 72.46 mm (2.8520 to 2.8528 in.)
U/S 0.75 72.19 to 72.21 mm (2.8421 to 2.8429 in.)
U/S 1.00 71.94 to 71.96 mm (2.8323 to 2.8330 in.)
Crankshaft journal radius Standard 3.00 to 3.50 mm (0.1181 to 0.1378 in.)
Connecting rod Thrust clearance Standard 0.20 to 0.52 mm (0.00787 to 0.0205 in.)
Maximum 0.60 mm (0.0236 in.)
Big end inside diameter (with bearing) Standard 61.991 to 62.022 mm (2.4406 to 2.4418 in.)
Maximum 62.06 mm (2.4433 in.)
Oil clearance Standard 0.031 to 0.082 mm (0.00122 to 0.00323 in.)
Maximum 0.20 mm (0.00787 in.)
Bearing diameter STD 61.94 to 61.96 mm (2.4386 to 2.4394 in.)
U/S 0.25 61.69 to 61.71 mm (2.4287 to 2.4295 in.)
U/S 0.50 61.44 to 61.46 mm (2.4189 to 2.4197 in.)
U/S 0.75 61.19 to 61.21 mm (2.4090 to 2.4098 in.)
U/S 1.00 60.94 to 60.96 mm (2.3992 to 2.4000 in.)
Camshaft Circle runout Maximum 0.06 mm (0.00236 in.)
Cam lobe height Standard Intake 50.31 to 50.51 mm (1.9807 to 1.9886 in.)
Exhaust 49.36 to 49.56 mm (1.9432 to 1.9511 in.)
Minimum Intake 49.85 mm (1.9626 in.)
Exhaust 48.95 mm (1.9272 in.)
Journal outside diameter Standard No. 1 56.95 to 56.97 mm (2.2421 to 2.2429 in.)
No. 2 56.75 to 56.77 mm (2.2343 to 2.2350 in.)
No. 3 56.55 to 56.57 mm (2.2264 to 2.2272 in.)
Inside diameter Standard No. 1 57.035 to 57.135 mm (2.2455 to 2.2494 in.)
No. 2 56.835 to 56.935 mm (2.2376 to 2.2415 in.)
No. 3 56.635 to 56.735 mm (2.2297 to 2.237 in.)
Oil clearance Standard 0.030 to 0.120 mm (0.00118 to 0.00472 in.)
Maximum 0.150 mm (0.00591 in.)
Crankshaft bearing cap set bolt Length Standard 92.80 to 93.80 mm (3.65 to 3.69 in.)
Maximum 95.00 mm (3.74 in.)
Camshaft bearing Journal bearing diameter Inside No. 1 57.0 mm (2.2441 in.)
No. 2 56.8 mm (2.2362 in.)
No. 3 56.6 mm (2.2283 in.)
Outside No. 1 60.0 mm (2.3622 in.)
No. 2 59.8 mm (2.3543 in.)
No. 3 59.6 mm (2.3465 in.)
ENGINE UNIT
No. 2 idle gear Thrust clearance Standard 0.103 to 0.164 mm (0.00406 to 0.00646 in.)
Maximum 0.30 mm (0.0118 in.)
Backlash Standard 0.036 to 0.166 mm (0.00142 to 0.00654 in.)
Maximum 0.30 mm (0.0118 in.)
Idle gear inside diameter Standard 50.000 to 50.025 mm (1.9685 to 1.9695 in.)
Maximum 50.05 mm (1.9704 in.)
Idle gear shaft diameter Standard 49.950 to 49.975 mm (1.9665 to 1.9675 in.)
Minimum 49.950 mm (1.9665 in.)
Oil clearance Standard 0.0125 to 0.0375 mm (0.000492 to 0.00148 in.)
Maximum 0.10 mm (0.00394 in.)
Camshaft timing gear Backlash Standard 0.068 to 0.171 mm (0.00268 to 0.00673 in.)
Maximum 0.30 mm (0.0118 in.)
Oil pump gear Backlash Standard 0.065 to 0.178 mm (0.00256 to 0.00701 in.)
Maximum 0.30 mm (0.0118 in.)
No. 1 idle gear Thrust clearance Standard 0.103 to 0.164 mm (0.00406 to 0.00646 in.)
Maximum 0.30 mm (0.0118 in.)
Backlash Standard 0.035 to 0.162 mm (0.00138 to 0.00638 in.)
Maximum 0.30 mm (0.0118 in.)
Idle gear inside diameter Standard 50.000 to 50.025 mm (1.9685 to 1.9695 in.)
Maximum 50.05 mm (1.9704 in.)
Idle gear shaft diameter Standard 49.950 to 49.975 mm (1.9665 to 1.9675 in.)
Minimum 49.950 mm (1.9665 in.)
Oil clearance Standard 0.0125 to 0.0370 mm (0.000492 to 0.00146 in.)
Maximum 0.10 mm (0.00394 in.)
Cylinder head set bolt Length Standard 126 mm (4.96 in.)
Maximum 129 mm (5.07 in.)
Valve rocker arm Bush inside diameter Standard 22.023 to 22.052 mm (0.8670 to 0.8681 in.)
Maximum 22.08 mm (0.8693 in.)
Shaft diameter Standard 21.959 to 21.980 mm (0.8645 to 0.8653 in.)
Minimum 21.92 mm (0.8630 in.)
Oil clearance Standard 0.043 to 0.093 mm (0.00169 to 0.00366 in.)
Maximum 0.15 mm (0.00591 in.)
Valve push rod Circle runout Maximum 0.30 mm (0.0118 in.)