| Vane pump V belt | Belt deflection | When replacing | 8.0 - 10.0 mm (0.31 - 0.39 in.) |
| When checking | 10.0 - 14.0 mm (0.39 - 0.55 in.) | ||
| Tension | When replacing | 440 - 540 N (45 - 55 kgf) | |
| When checking | 195 - 345 N (20 - 35 kgf) | ||
| Vane pump V-ribbed belt | Belt deflection | When replacing | 6.0 - 8.0 mm (0.24 - 0.31 in.) |
| When checking | 8.0 - 12.0 mm (0.31 - 0.47 in.) | ||
| Tension | When replacing | 540 - 400 N (55 - 65 kgf) | |
| When checking | 245 - 395 N (25 - 40 kgf) | ||
| V (cooler compressor to crankshaft pulley) belt No. 1 | Belt deflection | When replacing | 10.0 - 14.0 mm (0.39 - 0.56 in.) |
| When checking | 14.0 - 20.0 mm (0.55 - 0.79 in.) | ||
| Tension | When replacing | 372 - 608 N (38 - 62 kgf) | |
| When checking | 196 - 392 N (20 - 40 kgf) | ||
| Fan and generator V belt | Belt deflection | When replacing | 7.0 - 10.0 mm (0.28 - 0.39 in.) |
| When checking | 10.0 - 14.0 mm (0.39 - 0.56 in.) | ||
| Tension | When replacing | 430 N (44 - 55 kgf) | |
| When checking | 195 N - 345 N (20 - 35 kgf) | ||
| Injection timing | Plunger stroke | w/ TCV | 0.47 - 0.53 mm (0.0185 - 0.0209 in.) |
| w/o TCV | 0.67 - 0.73 mm (0.0265 - 0.0287 in.) | ||
| Injection nozzles | Nozzle opening pressure | New nozzle | 15,790 - 16,570 kPa (159 - 171 kgf/cm2, 2,290 - 2,404 psi) |
| Reused nozzle | 15,200 - 16,181 kPa (154 - 166 kgf/cm2, 2,205 - 2,347 psi) |
||
| Adjusting shim thickness | 0.900 mm (0.0354 in.) | ||
| 0.950 mm (0.0374 in.) | |||
| 1.000 mm (0.0394 in.) | |||
| 1.050 mm (0.0413 in.) | |||
| 1.100 mm (0.0433 in.) | |||
| 1.150 mm (0.0453 in.) | |||
| 1.200 mm (0.0472 in.) | |||
| 1.250 mm (0.0492 in.) | |||
| 1.300 mm (0.0512 in.) | |||
| 1.350 mm (0.0531 in.) | |||
| 1.400 mm (0.0551 in.) | |||
| 1.450 mm (0.0571 in.) | |||
| 1.500 mm (0.0591 in.) | |||
| 1.550 mm (0.0610 in.) | |||
| 1.600 mm (0.0630 in.) | |||
| 1.650 mm (0.0650 in.) | |||
| 1.700 mm (0.0669 in.) | |||
| 1.750 mm (0.0689 in.) | |||
| 1.800 mm (0.0709 in.) | |||
| 1.850 mm (0.0728 in.) | |||
| 1.900 mm (0.0748 in.) | |||
| 1.950 mm (0.0768 in.) | |||
| Idle speed | 650 - 750 rpm | ||
| Maximum speed | w/ TCV | 4,670 - 4,930 rpm | |
| w/o TCV | 4,770 - 5,030 rpm | ||
| Compression pressure | at 250 rpm STD | 3,138 kPa (32.0 kgf/cm2, 455 psi) or more |
|
| Minimum | 1,961 kPa (20.0 kgf/cm2, 284 psi) |
||
| Difference of pressure between each cylinder | 490 kPa (5.0 kgf/cm2, 71 psi) or less |
||
| Valve clearance (cold) | Intake | 0.20 - 0.30 mm (0.008 - 0.012 in.) | |
| Exhaust | 0.40 - 0.50 mm (0.016 - 0.020 in.) | ||
| Adjusting shim thickness (for repair part) | No. 01 | 2.50 mm (0.0984 in.) | |
| No. 42 | 2.55 mm (0.1004 in.) | ||
| No. 06 | 2.60 mm (0.1024 in.) | ||
| No. 43 | 2.65 mm (0.1043 in.) | ||
| No. 11 | 2.70 mm (0.1063 in.) | ||
| No. 44 | 2.75 mm (0.1083 in.) | ||
| No. 16 | 2.80 mm (0.1102 in.) | ||
| No. 45 | 2.85 mm (0.1122 in.) | ||
| No. 21 | 2.90 mm (0.1142 in.) | ||
| No. 46 | 2.95 mm (0.1161 in.) | ||
| No. 26 | 3.00 mm (0.1181 in.) | ||
| No. 47 | 3.05 mm (0.1201 in.) | ||
| No. 31 | 3.10 mm (0.1220 in.) | ||
| No. 48 | 3.15 mm (0.1240 in.) | ||
| No. 36 | 3.20 mm (0.1260 in.) | ||
| No. 49 | 3.25 mm (0.1280 in.) | ||
| No. 41 | 3.30 mm (0.1299 in.) | ||
| Cylinder head | Cylinder head bolt thread inside diameter | STD | 11.800 - 12.000 mm (0.4646 - 0.4724 in.) |
| Minimum | 11.60 mm (0.4567 in.) | ||
| Cylinder head gasket thickness | Mark B | 1.40 - 1.50 mm (0.0551 - 0.0591 in.) | |
| Mark D | 1.50 - 1.60 mm (0.0591 - 0.0630 in.) | ||
| Mark F | 1.60 - 1.70 mm (0.0630 - 0.0669 in.) | ||
| Piston | Piston protrusion from cylinder block | 0.68 - 0.97 mm (0.0268 - 0.0382 in.) | |
| Idler tension spring | Free length | 44.4 - 45.4 mm (1.748 - 1.787 in.) | |
| Installed load | at 52.1 mm (2.051 in.) | 53 - 59 N (5.42 - 5.98 kgf, 11.9 - 13.2 lbf) | |
| Cylinder head | Warpage | Maximum | 0.20 mm (0.0079 in.) |
| Valve seat refacing angle | Intake | 20°, 45°, 70° | |
| Exhaust | 20°, 45°, 75° | ||
| Valve seat contacting angle | 45° | ||
| Valve seat contacting width | Intake | 1.5 - 1.9 mm (0.059 - 0.075 in.) | |
| Exhaust | 1.8 - 2.2 mm (0.071 - 0.087 in.) | ||
| Valve guide bush | Inside diameter | 8.010 - 8.030 mm (0.3154 - 0.3161 in.) | |
| Outside diameter for repair part | STD | 13.040 - 13.051 mm (0.5134 - 0.5138 in.) | |
| O/S 0.05 | 13.090 - 13.101 mm (0.5154 - 0.5158 in.) | ||
| Valve | Valve overall length | STD Intake | 104.10 - 104.50 mm (4.0984 - 4.1142 in.) |
| STD Exhaust | 103.95 - 104.35 mm (4.0925 - 4.1083 in.) | ||
| Minimum Intake | 103.60 mm (4.0787 in.) | ||
| Minimum Exhaust | 103.45 mm (4.0728 in.) | ||
| Valve face angle | 44.5° | ||
| Stem diameter | Intake | 7.975 - 7.990 mm (0.3140 - 0.3146 in.) | |
| Exhaust | 7.960 - 7.975 mm (0.3134 - 0.3140 in.) | ||
| Stem oil clearance | STD Intake | 0.020 - 0.055 mm (0.0008 - 0.0022 in.) | |
| STD Exhaust | 0.035 - 0.070 mm (0.0014 - 0.0028 in.) | ||
| Maximum Intake | 0.08 mm (0.0031 in.) | ||
| Maximum Exhaust | 0.10 mm (0.0039 in.) | ||
| Margin thickness | STD Intake | 1.6 mm (0.063 in.) | |
| STD Exhaust | 1.7 mm (0.067 in.) | ||
| Maximum Intake | 1.1 mm (0.043 in.) | ||
| Maximum Exhaust | 1.2 mm (0.047 in.) | ||
| Valve spring | Deviation | Maximum | 2.0 mm (0.079 in.) |
| Free length | Type A | 46.20 mm (1.8189 in.) | |
| Type B | 48.54 mm (1.9110 in.) | ||
| Installed tension | at 37.0 mm (1.457 in.) | 301 - 322 N (30.7 - 33.9 kgf, 67.7 - 74.7 lbf) | |
| Valve lifter | Valve lifter inside diameter | 40.892 - 40.902 mm (1.6099 - 1.6103 in.) | |
| Cylinder head lifter bore diameter | 40.960 - 40.980 mm (1.6126 - 1.6134 in.) | ||
| Oil clearance | STD | 0.058 - 0.088 mm (0.0023 - 0.0035 in.) | |
| Maximum | 0.10 mm (0.0039 in.) | ||
| Camshaft | Circle runout | Maximum | 0.10 mm (0.0039 in.) |
| Cam lobe height | STD Intake | 54.290 - 54.310 mm (2.1374 - 2.1382 in.) | |
| STD Exhaust | 54.990 - 55.010 mm (2.1650 - 2.1657 in.) | ||
| Minimum Intake | 53.79 mm (2.1177 in.) | ||
| Minimum Exhaust | 54.49 mm (2.1453 in.) | ||
| Journal diameter | STD No. 1 | 34.969 - 34.985 mm (1.3767 - 1.3774 in.) | |
| Others | 27.969 - 27.985 mm (1.1011 - 1.1018 in.) | ||
| U/S 0.125 No. 1 | 34.844 - 34.860 mm (1.3718 - 1.3724 in.) | ||
| Others | 27.844 - 27.860 mm (1.0962 - 1.0968 in.) | ||
| U/S 0.250 No. 1 | 34.719 - 34.735 mm (1.3669 - 1.3675 in.) | ||
| Others | 27.719 - 27.735 mm (1.0913 - 1.0919 in.) | ||
| Journal oil clearance | STD | 0.022 - 0.074 mm (0.0009 - 0.0029 in.) | |
| Maximum | 0.10 mm (0.0039 in.) | ||
| Thrust clearance | STD | 0.080 - 0.280 mm (0.0031 - 0.0110 in.) | |
| Maximum | 0.35 mm (0.0138 in.) | ||
| Combustion chamber | Protrusion | Minus 0.03 - Plus 0.03 mm (Minus 0.0012 - Plus 0.0012 in.) | |
| Shim thickness | 0.03 mm (0.0012 in.) | ||
| Cylinder block | Cylinder head surface warpage | Maximum | 0.20 mm (0.0079 in.) |
| Cylinder bore diameter | STD Mark 1 | 99.500 - 95.510 mm (3.9173 - 3.9177 in.) | |
| STD Mark 2 | 99.510 - 95.520 mm (3.9177 - 3.9181 in.) | ||
| STD Mark 3 | 99.520 - 95.530 mm (3.9181 - 3.9185 in.) | ||
| Maximum STD | 99.73 mm (3.9264 in.) | ||
| O/S 0.50 | 100.23 mm (3.9461 in.) | ||
| Connecting rod | Thrust clearance | STD | 0.080 - 0.300 mm (0.0031 - 0.0118 in.) |
| Maximum | 0.35 mm (0.0138 in.) | ||
| Connecting rod oil clearance | STD | 0.036 - 0.064 mm (0.0014 - 0.0025 in.) | |
| U/S 0.25, U/S 0.50 | 0.033 - 0.079 mm (0.0013 - 0.0031 in.) | ||
| Maximum | 0.10 mm (0.0039 in.) | ||
| Connecting rod bearing center wall thickness (Reference) | STD Mark 1 | 1.478 - 1.482 mm (0.0582 - 0.0583 in.) | |
| STD Mark 2 | 1.482 - 1.486 mm (0.0583 - 0.0585 in.) | ||
| STD Mark 3 | 1.486 - 1.490 mm (0.0585 - 0.0587 in.) | ||
| Rod bent | Maximum per 100 mm (3.94 in.) | 0.05 mm (0.0020 in.) | |
| Rod twist | Maximum per 100 mm (3.94 in.) | 0.15 mm (0.0059 in.) | |
| Bush inside diameter | 29.008 - 29.020 mm (1.1420 - 1.1425 in.) | ||
| Piston pin diameter | 29.000 - 29.012 mm (1.1417 - 1.1422 in.) | ||
| Bushing oil clearance | STD | 0.004 - 0.012 mm (0.0002 - 0.0005 in.) | |
| Maximum | 0.05 mm (0.0020 in.) | ||
| Connecting rod bolt tension portion diameter | STD | 8.400 - 8.600 mm (0.3307 - 0.3386 in.) | |
| Maximum | 8.20 mm (0.3228 in.) | ||
| Piston and piston ring | Piston diameter | STD Mark 1 | 99.450 - 99.460 mm (3.9153 - 3.9157 in.) |
| STD Mark 2 | 99.460 - 99.470 mm (3.9157 - 3.9161 in.) | ||
| STD Mark 3 | 99.470 - 99.480 mm (3.9161 - 3.9165 in.) | ||
| O/S 0.50 | 99.950 - 99.980 mm (3.9350 - 3.9362 in.) | ||
| Piston oil clearance | STD | 0.040 - 0.060 mm (0.0016 - 0.0024 in.) | |
| Maximum | 0.13 mm (0.0051 in.) | ||
| Piston ring groove clearance | STD No. 1 | 0.057 - 0.101 mm (0.0022 - 0.0040 in.) | |
| STD No. 2 | 0.060 - 0.100 mm (0.0024 - 0.0039 in.) | ||
| Oil | 0.030 - 0.070 mm (0.0012 - 0.0028 in.) | ||
| Maximum | 0.20 mm (0.0079 in.) | ||
| Piston ring end gap | STD No. 1 | 0.350 - 0.590 mm (0.0138 - 0.0232 in.) | |
| STD No. 2 | 0.470 - 0.720 mm (0.0185 - 0.0283 in.) | ||
| Oil | 0.200 - 0.520 mm (0.0079 - 0.0205 in.) | ||
| Maximum No. 1 | 1.29 mm (0.0508 in.) | ||
| Maximum No. 2 | 1.42 mm (0.0559 in.) | ||
| Oil | 1.22 mm (0.0480 in.) | ||
| Piston protrusion from cylinder block | 0.68 - 0.97 mm (0.0268 - 0.0382 in.) | ||
| Crankshaft | Thrust clearance | STD | 0.040 - 0.250 mm (0.0016 - 0.0098 in.) |
| Maximum | 0.30 mm (0.0118 in.) | ||
| Thrust washer thickness | STD | 2.430 - 2.480 mm (0.0957 - 0.0976 in.) | |
| O/S 0.125 | 2.493 - 2.543 mm (0.0981 - 0.1001 in.) | ||
| O/S 0.250 | 2.555 - 2.605 mm (0.1006 - 0.1026 in.) | ||
| Main journal oil clearance | STD | 0.034 - 0.065 mm (0.0013 - 0.0026 in.) | |
| U/S 0.25, 0.50 | 0.033 - 0.079 mm (0.0013 - 0.0031 in.) | ||
| Maximum | 0.10 mm (0.0039 in.) | ||
| Main journal diameter | STD | 61.985 - 62.000 mm (2.4403 - 2.4409 in.) | |
| U/S 0.25 | 61.475 - 61.755 mm (2.4309 - 2.4413 in.) | ||
| U/S 0.50 | 61.495 - 61.505 mm (2.4211 - 2.4215 in.) | ||
| Main bearing center wall thickness (Reference) | STD Mark 1 | 1.979 - 1.983 mm (0.0779 - 0.0781 in.) | |
| STD Mark 2 | 1.983 - 1.987 mm (0.0781 - 0.0782 in.) | ||
| STD Mark 3 | 1.987 - 1.991 mm (0.0782 - 0.0784 in.) | ||
| Crank pin diameter | STD | 54.988 - 55.000 mm (2.1649 - 2.1654 in.) | |
| U/S 0.25 | 54.745 - 54.755 mm (2.1553 - 2.1557 in.) | ||
| U/S 0.50 | 54.495 - 54.505 mm (2.1455 - 2.1459 in.) | ||
| Circle runout | Maximum | 0.06 mm (0.0024 in.) | |
| Main journal taper and out-of-round | Maximum | 0.02 mm (0.0008 in.) | |
| Crank pin taper and out-of-round | Maximum | 0.02 mm (0.0008 in.) |