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

Engine speed Idling 700 to 800 rpm
Maximum 4300 to 4600 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.)
Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)
No. 1 timing belt tensioner assembly Protrusion Standard 8.1 to 8.9 mm (0.319 to 0.350 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.)
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.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance Standard 0.035 to 0.185 mm (0.0014 to 0.0073 in.)
Maximum 0.25 mm (0.0098 in.)
No. 2 camshaft Circle runout Maximum 0.03 mm (0.0012 in.)
Cam lobe height Standard 48.071 to 48.171 mm (1.8925 to 1.8965 in.)
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.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance Standard 0.035 to 0.185 mm (0.0014 to 0.0073 in.)
Maximum 0.25 mm (0.098 in.)
Camshaft timing gear Backlash Standard 0.035 to 0.089 mm (0.0014 to 0.0035 in.)
Maximum 0.189 mm (0.0074 in.)
Oil pump gear x Crankshaft timing gear Backlash Standard 0.02 to 0.15 mm (0.0008 to 0.0060 in.)
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.)
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.)
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.)
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.)
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.)
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.)
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.)
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.)
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.)
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.)
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.)
Maximum 0.40 mm (0.0157 in.)
Oil clearance Standard 0.036 to 0.054 mm (0.0014 to 0.0021 in.)
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.)
Minimum 8.30 mm (0.3268 in.)
Crankshaft Thrust clearance Standard 0.040 to 0.240 mm (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Oil clearance Standard 0.030 to 0.048 mm (0.0012 to 0.0019 in.)
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 (2.75566 to 2.75590 in.)

Mark 2: 69.988 to 69.994 mm (2.75543 to 2.75566 in.)

Mark 3: 69.982 to 69.988 mm (2.75519 to 2.75543 in.)
Crank pin diameter

Mark 1: 58.994 to 59.000 mm (2.32259 to 2.32283 in.)

Mark 2: 58.988 to 59.994 mm (2.32236 to 2.32259 in.)

Mark 3: 58.982 to 58.988 mm (2.32212 to 2.32239 in.)
Taper and out-of -round Maximum 0.020 mm (0.0008 in.)
Cylinder head set bolt Outside diameter Standard 11.76 to 11.97 mm (0.463 to 0.471 in.)
Minimum 11.6 mm (0.457 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.)
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 (3.77715 to 3.77755 in.)
Oil clearance Standard 0.070 to 0.090 mm (0.0028 to 0.0035 in.)
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.)
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.)
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.)
Minimum 12.60 mm (0.4961 in.)