5L-E ENGINE MECHANICAL SERVICE DATA

New drive belt deflection	Item	Specified condition
	For vane pump	8 to 10 mm (0.314 to 0.393 in.)
	For fan and generator	7.0 to 10 mm (0.276 to 0.393 in.)
	For Cooler compressor	11 to 15 mm (0.433 to 0.590 in.)
Used drive belt deflection	For vane pump	10.0 to 15 mm (0.393 to 0.590 in.)
	For fan and generator	10 to 14 mm (0.393 to 0.551 in.)
	For Cooler compressor	15 to 20 mm (0.590 to 0.787 in.)
New drive belt tension	For vane pump	441 to 539 N (45 to 55 kgf, 99.1 to 121.2 lbf)
	For fan and generator	441 to 539 N (45 to 55 kgf, 99.1 to 121.2 lbf)
	For Cooler compressor	372 to 608 N (38 to 62 kgf, 83.6 to 136.7 lbf)
Used drive belt tension	For vane pump	196 to 343 N (20 to 35 kgf, 44.1 to 77.1 lbf)
	For fan and generator	196 to 343 N (20 to 35 kgf, 44.1 to 77.1 lbf)
	For Cooler compressor	196 to 392 N (20 to 40 kgf, 44.1 to 88.1 lbf)
Idle speed		720 to 820 rpm
Maximum engine speed		4850 to 4950 rpm
Compression pressure		3138 kPa (32.0 kgf/cm², 455 psi) or higher
Minimum pressure		1961kPa (20.0 kgf/cm², 284 psi)
Difference between each cylinder		490 kPa (5.0 kgf/cm², 71 psi) or less
Valve clearance at cold	Intake	0.20 to 0.30 mm (0.00787 to 0.0118 in.)
Valve clearance at cold	Exhaust	0.40 to 0.50 mm (0.0158 to 0.0197 in.)
Cylinder head gasket
New installed cylinder head gasket thickness	Mark B	1.40 to 1.50 mm (0.0551 to 0.0591 in.)
	D	1.50 to 1.60 mm (0.0591 to 0.0630 in.)
	F	1.60 to 1.70 mm (0.0630 to 0.0669 in.)
New installed cylinder head gasket size	Mark B	0.68 to 0.78 mm (0.0268 to 0.0307 in.)
	D	0.78 to 0.88 mm (0.0307 to 0.0346 in.)
	F	0.88 to 0.98 mm (0.0346 to 0.0386 in.)
Idler tension spring
Free length		44.4 to 45.4 mm (1.75 to 1.79 in.)
Installed tension	at 52.1 mm (2.051 in.)	53 to 59 N (5.40 to 6.02 kgf, 11.9 to 13.3 lbf)
Cylinder head set bolt	Standard	11.80 to 12.00 mm (0.465 to 0.472 in.)
Outer diameter	Minimum	11.60 mm (0.457 in.)
Cylinder head gasket
Cylinder head
Warpage	Maximum	0.20 mm (0.00787 in.)
Intake Valve
Valve stem diameter		7.975 to 7.990 mm (0.3140 to 0.3146 in.)
Valve face angle		44.5°
Margin thickness	Standard	1.6 mm (0.0630 in.)
Margin thickness	Minimum	1.1 mm (0.0433 in.)
Overall length	Standard	104.10 to 104.50 mm (4.10 to 4.11 in.)
Overall length	Minimum	103.60 mm (4.08 in.)
Exhaust Valve
Valve stem diameter		7.960 to 7.975 mm (0.3134 to 0.3140 in.)
Valve face angle		44.5°
Margin thickness	Standard	1.7 mm (0.0669 in.)
Margin thickness	Minimum	1.2 mm (0.0472 in.)
Overall length	Standard	103.95 to 104.35 mm (4.09 to 4.11 in.)
Overall length	Minimum	103.45 mm (4.07 in.)
Valve spring
Deviation	Maximum	2.0 mm (0.0787 in.)
Free length		46.20 mm (1.82 in.)
Installed tension	at 37.0 mm (1.46 in.)	301 to 322 N (31 to 34 kgf, 66.6 to 74.6 lbf)
Intake valve guide bush
Inside diameter		8.010 to 8.030 mm (0.315 to 0.316 in.)
Oil clearance	Standard	0.020 to 0.055 mm (0.000787 to 0.00217 in.)
Oil clearance	Maximum	0.08 mm (0.00315 in.)
Bush bore diameter	STD	13.004 to 13.025 mm (0.512 to 0.513 in.)
Bush bore diameter	O/S 0.05	13.054 to 13.075 mm (0.514 to 0.515 in.)
Protrusion height		10.8 to 11.2 mm (0.425 to 0.441 in.)
Exhaust valve guide bush
Inside diameter		8.010 to 8.030 mm (0.315 to 0.316 in.)
Oil clearance	Standard	0.035 to 0.070 mm (0.00138 to 0.00276 in.)
Oil clearance	Maximum	0.10 mm (0.00394 in.)
Bush bore diameter	STD	13.004 to 13.025 mm (0.512 to 0.513 in.)
Bush bore diameter	O/S 0.05	13.054 to 13.075 mm (0.514 to 0.515 in.)
Protrusion height		10.8 to 11.2 mm (0.425 to 0.441 in.)
Intake valve seats
Contacting width		1.5 to 1.9 mm (0.0591 to 0.0748 in.)
Exhaust valve seats
Contacting width		1.8 to 2.2 mm (0.0708 to 0.0866 in.)
Valve lifter
Lifter diameter		40.892 to 40.902 mm (1.6099 to 1.6103 in.)
Lifter bore diameter		40.960 to 40.980 mm (1.6126 to 1.6134 in.)
Oil clearance	Standard	0.058 to 0.088 mm (0.00238 to 0.00346 in.)
Oil clearance	Maximum	0.10 mm (0.00394 in.)
Camshaft
Circle runout	Maximum	0.10 mm (0.0039 in.)
Cam lobe height	Standard
	Intake	54.890 to 54.910 mm (2.1610 to 2.1618 in.)
	Exhaust	54.990 to 55.010 mm (2.1650 to 2.1657 in.)
	Minimum
	Intake	54.39 mm (2.1413 in.)
	Exhaust	54.49 mm (2.1453 in.)
Journal diameter	STD No.1	34.969 to 34.985 mm (1.3767 to 1.3774 in.)
Journal diameter	Others	27.969 to 27.985 mm (1.101 to 1.102 in.)
Oil clearance	Standard	0.022 to 0.074 mm (0.000866 to 0.00291 in.)
Oil clearance	Maximum	0.10 mm (0.00394 in.)
Thrust clearance	Standard	0.080 to 0.280 mm (0.00351 to 0.0110 in.)
Thrust clearance	Maximum	0.35 mm (0.0138 in.)
Combustion chamber
Select a new combustion chamber	Mark 1	5.91 to 5.94 mm (0.2327 to 0.2338 in.)
	Mark 2	5.94 to 5.97 mm (0.2338 to 0.2350 in.)
	Mark 3	5.97 to 6.00 mm (0.2350 to 0.2362 in.)
Protrusion		- 0.03 to 0.03 mm (- 0.0012 to 0.0012 in.)
Connecting rod
Thrust clearance	Standard	0.080 to 0.300 mm (0.00315 to 0.0118 in.)
Thrust clearance	Maximum	0.35 mm (0.0138 in.)
Oil clearance	Standard
	STD	0.036 to 0.064 mm (0.00142 to 0.00252 in.)
	U/S 0.25, U/S 0.50	0.033 to 0.079 mm (0.00130 to 0.00311 in.)
	Maximum	0.10 mm (0.00394 in.)
Connecting rod bearing center wall thickness (Reference)	Standard
	Mark 1	1.478 to 1.482 mm (0.0582 to 0.0583 in.)
	2	1.482 to 1.486 mm (0.0583 to 0.0585 in.)
	3	1.486 to 1.490 mm (0.0585 to 0.0587 in.)
Rod bent	Maximum per 100 mm (3.94 in.)	0.05 mm (0.00196 in.)
Rod twist	Maximum per 100 mm (3.94 in.)	0.15 mm (0.00591 in.)
Bush inside diameter	Mark A	29.008 to 29.012 mm (1.1420 to 1.1422 in.)
	Mark B	29.012 to 29.016 mm (1.1422 to 1.1424 in.)
	Mark C	29.016 to 29.020 mm (1.1424 to 1.1425 in.)
Connecting rod bolt tension portion diameter	Standard	8.400 to 8.600 mm (0.331 to 0.339 in.)
Connecting rod bolt tension portion diameter	Minimum	8.20 mm (0.323 in.)
Crankshaft
Thrust clearance	Standard	0.040 to 0.250 mm (0.00157 to 0.00984 in.)
Thrust clearance	Maximum	0.30 mm (0.0118 in.)
Thrust washer thickness	STD	2.430 to 2.480 mm (0.0957 to 0.0976 in.)
	O/S 0.125	2.493 to 2.543 mm (0.0981 to 0.100 in.)
	O/S 0.250	2.555 to 2.605 mm (0.101 to 0.103 in.)
Main journal oil clearance	Standard
	STD	0.034 to 0.065 mm (0.00134 to 0.00256 in.)
	U/S 0.25, 0.50	0.033 to 0.079 mm (0.00130 to 0.00311 in.)
	Maximum	0.10 mm (0.00394 in.)
Main bearing center wall thickness (Reference)	Standard
	Mark 1	1.979 to 1.983 mm (0.0779 to 0.0781 in.)
	2	1.983 to 1.987 mm (0.0781 to 0.0782 in.)
	3	1.987 to 1.991 mm (0.0782 to 0.0784 in.)
Circle runout	Maximum	0.06 mm (0.00236 in.)
Main journal diameter	STD	61.985 to 62.000 mm (2.4403 to 2.4409 in.)
Crank pin diameter	STD	54.988 to 55.000 mm (2.1649 to 2.1654 in.)
Main journal taper and out-of round	Maximum	0.02 mm (0.000787 in.)
Cylinder block
Warpage	Maximum	0.20 mm (0.0079 in.)
Cylinder bore diameter	Mark 1	99.500 to 99.510 mm (3.9173 to 3.9177 in.)
	2	99.510 to 99.520 mm (3.9177 to 3.9181 in.)
	3	99.520 to 99.530 mm (3.9181 to 3.9185 in.)
	Maximum
	STD	99.73 mm (3.93 in.)
	O/S 0.50	100.23 mm (3.95 in.)
Piston
Piston diameter	STD
	Mark 1	99.450 to 99.460 mm (3.9153 to 3.9157 in.)
	2	99.460 to 99.470 mm (3.9157 to 3.9161 in.)
	3	99.470 to 99.480 mm (3.9161 to 3.9165 in.)
	O/S 0.50	99.950 to 99.980 mm (3.935 to 3.936 in.)
Oil clearance	Standard	0.040 to 0.060 mm (0.00157 to 0.00236 in.)
Oil clearance	Maximum	0.13 mm (0.00512 in.)
Piston pin
Diameter	Mark A	29.000 to 29.004 mm (1.1417 to 1.1419 in.)
	Mark B	29.004 to 29.008 mm (1.1419 to 1.1420 in.)
	Mark C	29.008 to 29.012 mm (1.1420 to 1.1422 in.)
Piston pin oil clearance	Standard	0.004 to 0.012 mm (0.000157 to 0.000472 in.)
Piston pin oil clearance	Maximum	0.05 mm (0.00197 in.)
Piston ring set
Piston ring groove clearance	Standard
	No.1	0.057 to 0.101 mm (0.00224 to 0.003980 in.)
	No.2	0.060 to 0.100 mm (0.00236 to 0.00394 in.)
	Oil	0.030 to 0.070 mm (0.00118 to 0.00276 in.)
	Maximum	0.20 mm (0.00787 in.)
Piston ring end gap	Standard
	No.1	0.350 to 0.470 mm (0.0138 to 0.0185 in.)
	No.2	0.470 to 0.600 mm (0.0185 to 0.0236 in.)
	Oil	0.200 to 0.400 mm (0.00787 to 0.0157 in.)
	Maximum
	No.1	1.29 mm (0.0508 in.)
	No.2	1.42 mm (0.0559 in.)
	Oil	1.22 mm (0.0480 in.)
Intake manifold
Warpage	Maximum	0.40mm (0.0157 in.)
Exhaust manifold
Warpage	Maximum	0.40mm (0.0157 in.)