1KD-FTV ENGINE MECHANICAL SERVICE DATA

Idle speed for Automatic Transmission 650 to 750 rpm
for Manual Transmission w/ DPF 650 to 750 rpm
w/o DPF 610 to 710 rpm
Maximum speed w/ DPF 4500 to 4700 rpm
w/o DPF 4450 to 4750 rpm
Compression pressure at 250 rpm or more Standard w/ DPF

2000 kPa (20.1 kgf/cm2, 280 psi) or higher
w/o DPF

2700 kPa (27.5 kgf/cm2, 391 psi) or higher
Minimum w/ DPF

1630 kPa (16.6 kgf/cm2, 236 psi) or higher
w/o DPF

2200 kPa (22.5 kgf/cm2, 320 psi) or higher
Difference between each cylinder

500 kPa (5.0 kgf/cm2, 71 psi) or less
Valve clearance Intake 0.2 to 0.3 mm (0.00787 to 0.0118 in.)
Exhaust 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
No. 1 timing belt tensioner Standard protrusion distance 8.1 to 8.9 mm (0.319 to 0.350 in.)
Cylinder head gasket New cylinder head gasket thickness A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)
Gasket size Use A 0.005 to 0.054 mm (0.000197 to 0.00213 in.)
Use B 0.055 to 0.104 mm (0.00217 to 0.00409 in.)
Use C 0.105 to 0.154 mm (0.00413 to 0.00606 in.)
Use D 0.155 to 0.204 mm (0.00610 to 0.00803 in.)
Use E 0.205 to 0.255 mm (0.00807 to 0.0100 in.)
Timing gear No. 1 idle gear thrust clearance Standard 0.06 to 0.11 mm (0.00236 to 0.00433 in.)
Maximum 0.3 mm (0.0118 in.)
Gear backlash Standard 0.02 to 0.15 mm (0.000787 to 0.00591 in.)
Maximum 0.2 mm (0.00787 in.)
Standard No. 1 idle gear inside diameter 44.000 to 44.025 mm (1.732 to 1.734 in.)
Standard idle gear shaft diameter 43.955 to 43.990 mm (1.730 to 1.732 in.)
Idle gear oil clearance Standard 0.01 to 0.07 mm (0.000394 to 0.00276 in.)
Maximum 0.20 mm (0.00787 in.)
Valve lifter Standard lifter diameter 30.966 to 30.976 mm (1.219 to 1.220 in.)
Standard cylinder head lifter bore diameter 31.000 to 31.021 mm (1.220 to 1.221 in.)
Oil clearance Standard 0.024 to 0.055 mm (0.000945 to 0.00217 in.)
Maximum 0.095 mm (0.00374 in.)
Intake manifold Maximum warpage 0.1 mm (0.00394 in.)
Exhaust manifold Maximum warpage 0.2 mm (0.00787 in.)
Camshaft Maximum circle runout 0.03 mm (0.00118 in.)
Cam lobe height Standard w/ DPF 46.99 to 47.09 mm (1.850 to 1.854 in.)
w/o DPF 47.18 to 47.28 mm (1.857 to 1.861 in.)
Minimum w/ DPF 46.57 mm (1.833 in.)
w/o DPF 47.76 mm (1.841 in.)
Standard journal diameter 27.969 to 27.985 mm (1.101 to 1.102 in.)
Journal oil clearance Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.1 mm (0.00394 in.)
Thrust clearance Standard 0.035 to 0.185 mm (0.00138 to 0.00728 in.)
Maximum 0.25 mm (0.00984 in.)
Gear backlash Standard 0.035 to 0.089 mm (0.00138 to 0.00350 in.)
Maximum 0.189 mm (0.00744 in.)
No. 2 camshaft Maximum circle runout 0.03 mm (0.00118 in.)
Cam lobe height Standard w/ DPF 48.31 to 48.41 mm (1.902 to 1.906 in.)
w/o DPF 48.07 to 48.17 mm (1.893 to 1.896 in.)
Minimum w/ DPF 48.16 mm (1.896 in.)
w/o DPF 47.92 mm (1.887 in.)
Standard journal diameter 27.969 to 27.985 mm (1.101 to 1.102 in.)
Journal oil clearance Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.1 mm (0.00394 in.)
Thrust clearance Standard 0.035 to 0.185 mm (0.00138 to 0.00728 in.)
Maximum 0.25 mm (0.00984 in.)
Gear backlash Standard 0.035 to 0.145 mm (0.0014 to 0.0057 in.)
Maximum 0.189 mm (0.00744 in.)
Cylinder head set bolt Standard outside diameter 11.76 to 11.97 mm (0.463 to 0.471 in.)
Minimum outside diameter 11.6 mm (0.457 in.)
Cylinder head Maximum warpage 0.15 mm (0.00591 in.)
Valve Standard stem diameter Intake 5.970 to 5.985 mm (0.235 to 0.236 in.)
Exhaust 5.960 to 52.975 mm (0.2346 to 0.352 in.)
Margin thickness Standard Intake 1.1 mm (0.0433 in.)
Exhaust 1.2 mm (0.0472 in.)
Minimum Intake 0.8 mm (0.0315 in.)
Exhaust 0.7 mm (0.0276 in.)
Overall length Standard Intake 105.15 to 105.75 mm (4.14 to 4.16 in.)
Exhaust 105.02 to 105.62mm (4.13 to 4.16 in.)
Minimum Intake 104.65 mm (4.12 in.)
Exhaust 104.52 mm (4.11 in.)
Inner compression spring Maximum deviation 2.0 mm (0.0787 in.)
Standard free length w/ DPF 48.4 mm (1.91 in.)
w/o DPF 46.5 mm (1.83 in.)
Installed tension at 33.1 mm (1.303 in.) w/ DPF 175 to 193 N (17.9 to 19.6 kgf, 39.4 to 43.3 lbf)
w/o DPF 175 to 193 N (15.3 to 16.9 kgf, 33.7 to 37.0 lbf)
Valve guide bush Inside diameter 6.01 to 6.03 mm (0.2366 to 0.2374 in.)
Stem oil clearance Standard Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Exhaust 0.035 to 0.070 mm (0.00138 to 0.00276 in.)
Maximum Intake 0.08 mm (0.00315 in.)
Exhaust 0.10 mm (0.00394 in.)
Valve Valve seat Contacting angle 45°
Contacting width Intake 1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Exhaust 1.6 to 2.0 mm (0.0630 to 0.0787 in.)
Bush bore diameter for repair part Use STD 10.985 to 11.006 mm (0.432 to 0.433 in.)
Use O/S 0.05 11.035 to 11.056 mm (0.434 to 0.435 in.)
Standard protrusion height (H) 10.3 to 10.7 mm (0.406 to 0.421 in.)
Valve seat (Refacing angle) Intake 25°, 45°, 70°
Exhaust 25°, 45°, 75°
Cylinder block Cylinder head surface warpage Maximum 0.1 mm (0.00394 in.)
Cylinder bore diameter Standard Mark 1 96.00 to 96.01 mm (3.7795 to 3.7799 in.)
Mark 2 96.01 to 96.02 mm (3.7799 to 3.7803 in.)
Mark 3 96.02 to 96.03 mm (3.7803 to 3.7807 in.)
Maximum diameter 96.23 mm (3.7886 in.)
O/S 0.50 96.50 to 96.53 mm (3.7992 to 3.8004 in.)
Maximum 96.73 mm (3.8083 in.)
O/S 0.75 96.75 to 96.78 mm (3.8090 to 3.8102 in.)
Maximum 96.98 mm (3.8181 in.)
O/S 1.00 97.00 to 97.03 mm (3.8189 to 3.8201 in.)
Maximum 97.23 mm (3.8280 in.)
Piston and piston ring Piston diameter Standard Mark 1 95.92 to 95.93 mm (3.7764 to 3.7768 in.)
Mark 2 95.93 to 95.94 mm (3.7768 to 3.7772 in.)
Mark 3 95.94 to 95.95 mm (3.7772 to 3.7776 in.)
O/S 0.50 96.42 to 96.45 mm (3.7960 to 3.7972 in.)
O/S 0.75 96.67 to 96.70 mm (3.8059 to 3.8070 in.)
O/S 1.00 96.92 to 96.95 mm (3.8157 to 3.8169 in.)
Piston pin diameter Standard Mark A 34.000 to 34.004 mm (1.3386 to 1.3387 in.)
Standard Mark B 34.004 to 34.008 mm (1.3387 to 1.3389 in.)
Standard Mark C 34.008 to 34.009mm (1.3389 to 1.3391 in.)
Piston oil clearance Standard 0.07 to 0.09 mm (0.00276 to 0.00354 in.)
Maximum 0.14 mm (0.00551 in.)
Groove clearance Standard

w/ DPF

No. 1 piston ring

 0.091 to 0.135 mm (0.00358 to 0.00531 in.)
No. 2 piston ring 0.090 to 0.135 mm (0.00354 to 0.00531 in.)
Oil ring 0.030 to 0.075 mm (0.00118 to 0.00295 in.)
Ring end gap Standard No. 1 piston ring 0.27to 0.39mm (0.0106 to 0.0154 in.)
No. 2 piston ring 0.55 to 0.70 mm (0.0217 to 0.0276 in.)
Oil ring 0.20 to 0.40 mm (0.00787 to 0.0157 in.)
Maximum No. 1 piston ring 0.85 mm (0.0335 in.)
No. 2 piston ring 1.07 mm (0.0421 in.)
Oil ring 0.77 mm (0.0303 in.)
Piston protrusion from cylinder block 0.005 to 0.255 mm (0.000197 to 0.0100 in.)
Connecting rod Thrust clearance Standard 0.1 to 0.3 mm (0.00394 to 0.0118 in.)
Maximum 0.4 mm (0.0157 in.)
Connecting rod oil clearance Standard 0.036 to 0.054 mm (0.00142 to 0.00212 in.)
U/S 0.25, U/S 0.50 0.037 to 0.077 mm (0.00146 to 0.00303 in.)
Maximum 0.1 mm (0.00394 in.)
Standard sized connecting rod bearing center wall thickness Mark 2 1.486 to 1.489 mm (0.0585 to 0.0586 in.)
Mark 3 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
Mark 4 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
Mark 5 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
Mark 6 1.498 to 1.501 mm (0.0590 to 0.0591 in.)
Bush inside diameter Mark A 34.012 to 34.016 mm (1.3390 to 1.3392 in.)
Mark B 34.016 to 34.020 mm (1.3392 to 1.3393 in.)
Mark C 34.020 to 34.024 mm (1.3393 to 1.3395 in.)
Piston pin oil clearance Standard 0.008 to 0.016 mm (0.000315 to 0.000630 in.)
Maximum 0.03 mm (0.0113 in.)
Rod bend Maximum per 100 mm (3.94 in.) 0.03 mm (0.00118 in.) per 100 mm (3.94 in.)
Rod twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Connecting rod bolt Standard 8.5 to 8.6 (0.335 to 0.339 in.)
Minimum 8.3 mm (0.327 in.)
Balanceshaft Standard bearing inside diameter No. 1 42.000 to 42.020 mm (1.6535 to 1.6543 in.)
No. 2 41.000 to 41.020 mm (1.6142 to 1.6150 in.)
No. 3 32.000 to 32.020 mm (1.2598 to 1.2606 in.)
Standard main journal diameter No. 1 41.941 to 41.960 mm (1.6512 to 1.6520 in.)
No. 2 40.931 to 40.950 mm (1.6115 to 1.6122 in.)
No. 3 31.941 to 31.960 mm (1.2575 to 1.2583 in.)
Balanceshaft thrust clearance Standard 0.065 to 0.140 mm (0.00256 to 0.00551 in.)
Maximum 0.25 mm (0.00984 in.)
Standard clearance No. 1 0.040 to 0.079 mm (0.00157 to 0.00311 in.)
No. 2 0.050 to 0.089 mm (0.00197 to 0.00350 in.)
No. 3 0.040 to 0.079 mm (0.00157 to 0.00311 in.)
Maximum clearance No. 1 0.18 mm (0.00709 in.)
No. 2 0.19 mm (0.00748 in.)
No. 3 0.18 mm (0.00709 in.)
Crankshaft Thrust clearance Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Maximum 0.3 mm (0.0118 in.)
Standard thrust washer thickness Standard 2.430 to 2.480 mm (0.0957 to 0.0976 in.)
U/S 0.125 2.555 to 2.605 mm (0.1005 to 0.1025 in.)
U/S 0.250 2.680 to 2.730 mm (0.1055 to 0.1074 in.)
Main journal oil clearance Standard 0.030 to 0.048 mm (0.00118 to 0.00189 in.)
U/S 0.25, U/S 0.50 0.037 to 0.077 mm (0.00146 to 0.00303 in.)
Maximum 0.1 mm (0.00394 in.)
Standard connecting rod big end inside diameter Mark 1 62.014 to 62.020 mm (2.4415 to 2.4417 in.)
Mark 2 62.020 to 62.026 mm (2.4417 to 2.4420 in.)
Mark 3 62.026 to 62.032 mm (2.4420 to 2.4422 in.)
Standard cylinder block main journal bore diameter Mark 1 75.000 to 75.006 mm (2.9528 to 2.9530 in.)
Mark 2 75.006 to 75.012 mm (2.9530 to 2.9532 in.)
Mark 3 75.012 to 75.018 mm (2.9532 to 2.9535 in.)
Standard crankshaft 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.)
U/S 0.25 69.745 to 69.755 mm (2.7459 to 2.7463 in.)
U/S 0.50 69.495 to 69.505 mm (2.7360 to 2.7364 in.)
Crankshaft Standard sized main bearing center wall thickness Mark 2 2.482 to 2.485 mm (0.0977 to 0.0978 in.)
Mark 3 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
Mark 4 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
Mark 5 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
Mark 6 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
Standard crank pin diameter Mark 1 58.994 to 59.000 mm (2.3226 to 2.3228 in.)
Mark 2 58.988 to 58.994 mm (2.3224 to 2.3226 in.)
Mark 3 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
U/S 0.25 58.745 to 58.755 mm (2.3128 to 2.3132 in.)
U/S 0.50 58.495 to 58.505 mm (2.3029 to 2.3033 in.)
Circle runout Maximum 0.03 mm (0.00118 in.)
Main journal taper and out-of-round Maximum 0.02 mm (0.00787 in.)
Crank pin taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crankshaft bearing cap bolt Standard 13.5 to 14.0 mm (0.531 to 0.551 in.)
Minimum 12.6 mm (0.496 in.)