1KD-FTV ENGINE MECHANICAL (w/ DPF) SERVICE DATA

Engine speed		Idling	700 to 800 rpm
Engine speed		Maximum	4500 to 4700 rpm
Compression pressure		Standard	2000 kPa (20.1 kgf/cm², 290 psi)
		Minimum	1630kPa (16.6 kgf/cm², 236 psi)
		Difference between each cylinder	500 kPa (5.0 kgf/cm², 71 psi) or more
Valve clearance (cold)	Intake		0.20 to 0.30 mm (0.008 to 0.012 in.)
Valve clearance (cold)	Exhaust		0.35 to 0.45 mm (0.014 to 0.018 in.)
Camshaft	Circle runout	Maximum	0.03 mm (0.0012 in.)
	Cam lobe height	Standard	47.180 to 47.280 mm (1.8575 to 1.8614 in.)
	Cam lobe height	Minimum	46.760 mm (1.8409 in.)
	Journal diameter	Standard	27.969 to 27.985 mm (1.1011 to 1.1018 in.)
	Oil clearance	Standard	0.025 to 0.062 mm (0.0010 to 0.0024 in.)
	Oil clearance	Maximum	0.10 mm (0.0039 in.)
	Thrust clearance	Standard	0.035 to 0.185 mm (0.0014 to 0.0073 in.)
	Thrust clearance	Maximum	0.25 mm (0.0098 in.)
No. 2 camshaft	Circle runout	Maximum	0.03 mm (0.0012 in.)
	Cam lobe height	Standard	48.070 to 48.170 mm (1.8925 to 1.8965 in.)
	Cam lobe height	Minimum	47.920 mm (1.8866 in.)
	Journal diameter	Standard	27.969 to 27.985 mm (1.1011 to 1.1018 in.)
	Oil clearance	Standard	0.025 to 0.062 mm (0.0010 to 0.0024 in.)
	Oil clearance	Maximum	0.10 mm (0.0039 in.)
	Thrust clearance	Standard	0.035 to 0.185 mm (0.0014 to 0.0073 in.)
	Thrust clearance	Maximum	0.25 mm (0.098 in.)
Camshaft timing gear	Backlash	Standard	0.035 to 0.089 mm (0.0014 to 0.0035 in.)
Camshaft timing gear	Backlash	Maximum	0.189 mm (0.0074 in.)
Cylinder head sub-assembly	Warpage	Maximum	0.15 mm (0.005 in.)
Intake valve	Valve stem diameter	Standard	5.970 to 5.985 mm (0.2350 to 0.2356 in.)
	Valve face angle	Standard	44.5°
	Margin thickness	Standard	1.1 mm (0.043 in.)
	Margin thickness	Minimum	0.8 mm (0.032 in.)
	Overall length	Standard	105.15 to 105.75 mm (4.1398 to 4.1634 in.)
	Overall length	Minimum	104.65 mm (4.1201 in.)
Exhaust valve	Valve stem diameter	Standard	5.960 to 5.975 mm (0.2346 to 0.2352 in.)
	Valve face angle	Standard	44.5°
	Margin thickness	Standard	1.2 mm (0.047 in.)
	Margin thickness	Minimum	0.7 mm (0.028 in.)
	Overall length	Standard	105.02 to 105.62 mm (4.1347 to 4.1583 in.)
	Overall length	Minimum	104.52 mm (4.1150 in.)
Inner compression spring	Deviation	Maximum	2.0 mm (0.079 in.)
	Free length	Standard	48.43 mm (1.907 in.)
	Installed tension (at 33.1 mm (1.303 in.))	Standard	174.8 to 193.2 N (17.9 to 19.6 kgf, 39.4 to 43.3 lbf)
Intake valve guide bush	Bush inside diameter	Standard	6.01 to 6.03 mm (0.2366 to 0.2374 in.)
	Oil clearance	Standard	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
	Oil clearance	Maximum	0.08 mm (0.0032 in.)
Exhaust valve guide bush	Bush inside diameter	Standard	6.01 to 6.03 mm (0.2366 to 0.2374 in.)
	Oil clearance	Standard	0.035 to 0.070 mm (0.0014 to 0.0028 in.)
	Oil clearance	Maximum	0.10 mm (0.0039 in.)
Intake valve seat	Width	Standard	1.2 to 1.6 mm (0.047 to 0.063 in.)
Exhaust valve seat	Width	Standard	1.6 to 2.0 mm (0.063 to 0.079 in.)
Valve lifter	Oil clearance	Standard	0.024 to 0.055 mm (0.0009 to 0.0022 in.)
Valve lifter	Oil clearance	Maximum	0.095 mm (0.0037 in.)
Cylinder head set bolt	Outside diameter	Standard	11.76 to 11.97 mm (0.463 to 0.471 in.)
Cylinder head set bolt	Outside diameter	Minimum	11.6 mm (0.457 in.)
Oil pump gear x Crankshaft timing gear	Backlash	Standard	0.02 to 0.15 mm (0.0008 to 0.0060 in.)
Oil pump gear x Crankshaft timing gear	Backlash	Maximum	0.20 mm (0.0079 in.)
Oil pump gear x No. 1 balance shaft	Backlash	Standard	0.02 to 0.15 mm (0.0008 to 0.0060 in.)
Oil pump gear x No. 1 balance shaft	Backlash	Maximum	0.20 mm (0.0079 in.)
No. 1 idle gear	Thrust clearance	Standard	0.06 to 0.11 mm (0.0024 to 0.00043 in.)
	Thrust clearance	Maximum	0.30 mm (0.0118 in.)
	Inside diameter	Standard	44.000 to 44.025 mm (1.7323 to 1.7333 in.)
	Oil clearance	Standard	0.010 to 0.070 mm (0.0004 to 0.0028 in.)
	Oil clearance	Maximum	0.20 mm (0.0079 in.)
Idle gear shaft	Diameter	Standard	43.955 to 43.990 mm (1.7305 to 1.7319 in.)
Crankshaft timing gear	Backlash	Standard	0.02 to 0.15 mm (0.0008 to 0.0060 in.)
Crankshaft timing gear	Backlash	Maximum	0.20 mm (0.0079 in.)
Injection gear x No. 2 balance shaft	Backlash	Standard	0.02 to 0.15 mm (0.0008 to 0.0060 in.)
Injection gear x No. 2 balance shaft	Backlash	Maximum	0.20 mm (0.0079 in.)
Injection gear x Idle gear	Backlash	Standard	0.02 to 0.15 mm (0.0008 to 0.0060 in.)
Injection gear x Idle gear	Backlash	Maximum	0.20 mm(0.0079 in.)
No. 1 balance shaft sub-assembly	Thrust clearance	Standard	0.065 to 0.140 mm (0.0026 to 0.0055 in.)
	Thrust clearance	Maximum	0.25 mm (0.0098 in.)
	Oil clearance	Standard	No. 1: 0.040 to 0.079 mm (0.0016 to 0.0031 in.) No. 2: 0.050 to 0.089 mm (0.0020 to 0.0035 in.) Oil: 0.004 to 0.079 mm (0.0016 to 0.0031 in.)
	Oil clearance	Maximum	No. 1: 0.18 mm (0.0071 in.) No. 2: 0.19 mm (0.0075 in.) Oil: 0.18 mm (0.0071 in.)
No. 2 balance shaft sub-assembly	Thrust clearance	Standard	0.065 to 0.140 mm (0.0026 to 0.0055 in.)
	Thrust clearance	Maximum	0.25 mm (0.0098 in.)
	Oil clearance	Standard	No. 1: 0.040 to 0.079 mm (0.0016 to 0.0031 in.) No. 2: 0.050 to 0.089 mm (0.020 to 0.0035 in.) Oil: 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
	Oil clearance	Maximum	No. 1: 0.18 mm (0.0071 in.) No. 2: 0.19 mm (0.0075 in.) Oil: 0.18 mm (0.0071 in.)
Connecting rod	Thrust clearance	Standard	0.100 to 0.300 mm (0.0039 to 0.0118 in.)
	Thrust clearance	Maximum	0.40 mm (0.0157 in.)
	Oil clearance	Standard	0.036 to 0.054 mm (0.0014 to 0.0021 in.)
	Oil clearance	Maximum	0.10 mm (0.0039 in.)
	Bend	Maximum	0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
	Twist	Maximum	0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
Connecting rod bolt	Diameter	Standard	8.500 to 8.600 mm (0.3346 to 0.3385 in.)
Connecting rod bolt	Diameter	Minimum	8.30 mm (0.3268 in.)
Crankshaft	Thrust clearance	Standard	0.040 to 0.240 mm (0.0016 to 0.0094 in.)
	Thrust clearance	Maximum	0.30 mm (0.0118 in.)
	Oil clearance	Standard	0.030 to 0.048 mm (0.0012 to 0.0019 in.)
	Oil clearance	Maximum	0.10 mm (0.0039 in.)
	Circle runout	Maximum	0.03 mm (0.0012 in.)
	Main journal diameter		Mark 1: 69.994 to 70.000 mm (2.7557 to 2.7559 in.) Mark 2: 69.988 to 69.994 mm (2.7554 to 2.7557 in.) Mark 3: 69.982 to 69.988 mm (2.7552 to 2.7554 in.)
	Crank pin diameter		Mark 1: 58.994 to 59.000 mm (2.3226 to 2.3228 in.) Mark 2: 58.988 to 59.994 mm (2.3224 to 2.3226 in.) Mark 3: 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
	Taper and out-of -round	Maximum	0.020 mm (0.0008 in.)
Cylinder block sub-assembly	Warpage	Maximum	0.10 mm (0.0039 in.)
	Bore diameter	Standard	Mark 1: 96.000 to 96.010 mm (3.7795 to 3.7799 in.) Mark 2: 96.010 to 96.020 mm (3.7799 to 3.7803 in.) Mark 3: 96.020 to 96.030 mm (3.7803 to 3.7807 in.)
	Bore diameter	Maximum	96.23 mm (3.7886 in.)
Piston	Diameter	Standard	Mark 1: 95.92 to 95.93 mm (3.77637 to 3.77676 in.) Mark 2: 95.93 to 95.94 mm (3.77676 to 3.77715 in.) Mark 3: 95.94 to 95.95 mm (3.77716 to 3.77755 in.)
	Oil clearance	Standard	0.070 to 0.090 mm (0.0028 to 0.0035 in.)
	Oil clearance	Maximum	0.14 mm (0.0055 in.)
Piston pin	Diameter	Standard	Mark A: 34.000 to 34.004 mm (1.3386 to 1.3387 in.) Mark B: 34.004 to 34.008 mm (1.3387 to 1.3389 in.) Mark C: 34.008 to 34.012 mm (1.3389 to 1.3391 in.)
	Oil clearance	Standard	0.008 to 0.016 mm (0.0003 to 0.0006 in.)
	Oil clearance	Maximum	0.03 mm (0.012 in.)
Piston ring	Ring groove clearance		No. 1: 0.091 to 0.135 mm (0.0036 to 0.0053 in.) No. 2: 0.090 to 0.135 mm (0.0036 to 0.0053 in.) Oil: 0.030 to 0.075 mm (0.0012 to 0.0030 in.)
	End gap	Standard	No. 1: 0.27 to 0.39 mm (0.0106 to 0.0154 in.) No. 2: 0.55 to 0.70 mm (0.0217 to 0.0276 in.) Oil: 0.20 to 0.40 mm (0.0079 to 0.0157 in.)
	End gap	Maximum	No. 1: 0.85 mm (0.03355 in.) No. 2: 1.07 mm (0.0421 in.) Oil: 0.77 mm (0.0303 in.)
Crankshaft bearing cap set bolt	Diameter	Standard	13.500 to 14.000 mm (0.5315 to 0.5512 in.)
Crankshaft bearing cap set bolt	Diameter	Minimum	12.60 mm (0.4961 in.)