1VD-FTV ENGINE MECHANICAL SERVICE DATA

ENGINE
Standard idle speed for Manual Transmission 500 to 600 rpm
for Automatic Transmission 550 to 750 rpm
Maximum engine speed 4700 to 4900 rpm
Compression Standard pressure (normal condition)

2700 kPa (27.5 kgf/cm2, 392 psi)
Minimum pressure

2200 kPa (22.4 kgf/cm2, 319 psi)
Difference between end cylinder

500 kPa (5.1 kgf/cm2, 73 psi) or less
DRIVE BELT

w/ Viscous Heater:

Standard belt tension

 New belt 5 to 35°C (41 to 95°F) 550 to 800 N (56 to 82 kgf, 123.6 to 179.8 lbf)
Used belt 5 to 35°C (41 to 95°F) 300 to 500 N (31 to 51 kgf, 67.4 to 112.4 lbf)

  • A "new belt" is a belt which has been used for less than 5 minutes on a running engine.

  • A "used belt" is a belt which has been used on a running engine for 5 minutes or more.

  • After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension.
CYLINDER HEAD GASKET
Select No. 1 and No. 2 cylinder head gasket Standard piston protrusion 0.520 to 0.780 mm (0.0205 to 0.0307 in.)

New installed cylinder head gasket thickness

(HINT: The specified condition indicates the gaskets thickness after tightening the cylinder head.)

 1 cutout (item A) 1.20 to 1.30 mm (0.0472 to 0.0512 in.)
2 cutouts (item B) 1.25 to 1.35 mm (0.0492 to 0.0394 in.)
3 cutouts (item C) 1.30 to 1.40 mm (0.0512 to 0.0551 in.)
4 cutouts (item D) 1.35 to 1.45 mm (0.0531 to 0.0571 in.)
5 cutouts (item E) 1.40 to 1.50 mm (0.0551 to 0.0591 in.)
Piston protrusion Item A 0.520 to 0.575 mm (0.0205 to 0.0226 in.)
Item B 0.575 to 0.625 mm (0.0226 to 0.0246 in.)
Item C 0.625 to 0.675 mm (0.0246 to 0.0266 in.)
Item D 0.675 to 0.725 mm (0.0266 to 0.0285 in.)
Item E 0.725 to 0.780 mm (0.0285 to 0.0307 in.)
ENGINE UNIT
Connecting rod Standard oil clearance 0.024 to 0.042 mm (0.000945 to 0.00165 in.)
Maximum oil clearance 0.052 mm (0.00205 in.)
Connecting rod bolt Standard diameter 8.7 to 8.8 mm (0.343 to 0.346 in.)
Minimum diameter 8.5 mm (0.335 in.)
Alignment Maximum bend 0.07 mm (0.00276 in.) per 100 mm (3.94 in.)
Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Connecting rod bearing Standard bearing center wall thickness Mark 1 More than 1.485 to 1.488 mm (more than 0.05846 to 0.05858 in.)
Mark 2 More than 1.488 to 1.491 mm (more than 0.05858 to 0.05870 in.)
Mark 3 More than 1.491 to 1.494 mm (more than 0.05870 to 0.05882 in.)
Mark 4 More than 1.494 to 1.497 mm (more than 0.05882 to 0.05894 in.)
Mark 5 More than 1.497 to 1.500 mm (more than 0.05894 to 0.05910 in.)
Standard connection rod big end inside diameter Mark 1 58.000 to 58.006 mm (2.28346 to 2.28370 in.)
Mark 2 More than 58.006 to 58.012 mm (more than 2.28370 to 2.28393 in.)
Mark 3 More than 58.012 to 58.018 mm (more than 2.28393 to 2.28417 in.)
Standard crankshaft pin diameter Mark 0 More than 54.994 to 55.000 mm (more than 2.16511 to 2.16535 in.)
Mark 1 More than 54.988 to 54.994 mm (more than 2.16488 to 2.16511 in.)
Mark 2 54.982 to 54.988 mm (2.16464 to 2.16488 in.)
Crankshaft Maximum circle runout 0.04 mm (0.00157 in.)
Main journal Standard diameter 74.982 to 75.000 mm (2.9520 to 2.9527 in.)
Maximum taper and out-of-round 0.01 mm (0.000394 in.)
Crank pin Standard diameter 54.982 to 55.000 mm (2.1646 to 2.1653 in.)
Maximum taper and out-of-round 0.01 mm (0.000394 in.)
Oil clearance Standard No. 1 and 3 journals 0.020 to 0.038 mm (0.000787 to 0.00150 in.)
No. 2, 4 and 5 journals 0.032 to 0.050 mm (0.00126 to 0.00197 in.)
Maximum 1 and 3 journals 0.048mm (0.00189 in.)
No. 2, 4 and 5 journals 0.060mm (0.00236 in.)
Main journal diameter No. 1 and 3 journals '2' More than 74.994 to 75.000 mm (more than 2.95251 to 2.95275 in.)
'3' More than 74.988 to 74.994 mm (more than 2.95228 to 2.95251 in.)
'4' 74.982 to 74.988 mm (2.95204 to 2.95228 in.)
No. 2, 4 and 5 journals '0' More than 74.994 to 75.000 mm (more than 2.95251 to 2.95275 in.)
'1' More than 74.988 to 74.994 mm (more than 2.95288 to 2.95251 in.)
'2' 74.982 to 74.988 mm (2.95204 to 2.95228 in.)
Crankshaft bearing No. 1 and 5 journal bearings wide 22.5 mm (0.886 in.)
No. 2, 3 and 4 journal bearings wide 20.5 mm (0.807 in.)
Center wall thickness (for upper bearing) No. 1 and 5 journal bearings '1' More than 1.987 to 1.990 mm (more than 0.07823 to 0.07835 in.)
'2' More than 1.990 to 1.993 mm (more than 0.07835 to 0.07846 in.)
'3' More than 1.993 to 1.996 mm (more than 0.07846 to 0.07858 in.)
'4' More than 1.996 to 1.999 mm (more than 0.07858 to 0.07870 in.)
'5' More than 1.999 to 2.002 mm (more than 0.07870 to 0.07882 in.)
'6' More than 2.002 to 2.005 mm (more than 0.07882 to 0.07894 in.)
'7' More than 2.005 to 2.008 mm (more than 0.07894 to 0.07905 in.)
No. 2, 3 and 4 journal bearings '1' More than 1.975 to 1.978 mm (more than 0.07776 to 0.07787 in.)
'2' More than 1.978 to 1.981 mm (more than 0.07787 to 0.07799 in.)
'3' More than 1.981 to 1.984 mm (more than 0.07799 to 0.07811 in.)
'4' More than 1.984 to 1.987 mm (more than 0.07811 to 0.07823 in.)
'5' More than 1.987 to 1.990 mm (more than 0.07823 to 0.07835 in.)
'6' More than 1.990 to 1.993 mm (more than 0.07835 to 0.07846 in.)
'7' More than 1.993 to 1.996 mm (more than 0.07846 to 0.07858 in.)
Crankshaft bearing Center wall thickness (for lower bearing) No. 1 and 5 journal bearings '1' More than 1.975 to 1.978 mm (more than 0.07776 to 0.07787 in.)
'2' More than 1.978 to 1.981 mm (more than 0.07787 to 0.07799 in.)
'3' More than 1.981 to 1.984 mm (more than 0.07799 to 0.07811 in.)
'4' More than 1.984 to 1.987 mm (more than 0.07811 to 0.07823 in.)
'5' More than 1.987 to 1.990 mm (more than 0.07823 to 0.07835 in.)
'6' More than 1.990 to 1.993 mm (more than 0.07835 to 0.07846 in.)
'7' More than 1.993 to 1.996 mm (more than 0.07846 to 0.07858 in.)
No. 2, 3 and 4 journal bearings '1' More than 1.987 to 1.990 mm (more than 0.07823 to 0.07835 in.)
'2' More than 1.990 to 1.993 mm (more than 0.07835 to 0.07846 in.)
'3' More than 1.993 to 1.996 mm (more than 0.07846 to 0.07858 in.)
'4' More than 1.996 to 1.999 mm (more than 0.07858 to 0.07870 in.)
'5' More than 1.999 to 2.002 mm (more than 0.07870 to 0.07882 in.)
'6' More than 2.002 to 2.005 mm (more than 0.07882 to 0.07894 in.)
'7' More than 2.005 to 2.008 mm (more than 0.07894 to 0.07905 in.)
Cylinder head Standard warpage Cylinder block side 0 to 0.05 mm (0 to 0.00197 in.)
Intake manifold side 0 to 0.08 mm (0 to 0.00315 in.)
Exhaust manifold side 0 to 0.08 mm (0 to 0.00315 in.)
Maximum warpage Cylinder block side 0.05 mm (0.00197 in.)
Intake manifold side 0.08 mm (0.00315 in.)
Exhaust manifold side 0.08 mm (0.00315 in.)
Inner compression spring Maximum deviation 1.5 mm (0.0591 in.)
Standard free length 45.9 mm (1.81 in.)
Installed tension 219 to 242 N (22 to 25 kgf, 49.2 to 54.4 lbf) at 31.0 mm (1.22 in.)
Valve guide bush oil clearance Standard bush inside diameter 6.01 to 6.03 mm (0.2366 to 0.2374 in.)
Standard oil clearance 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 oil clearance Intake 0.120 mm (0.00472 in.)
Exhaust 0.130 mm (0.00512 in.)
Valve Standard valve stem diameter Intake 5.970 to 5.985 mm (0.2350 to 0.2356 in.)
Exhaust 5.960 to 5.975 mm (0.2346 to 0.2352 in.)
Standard overall length Intake 104.4 mm (4.11 in.)
Exhaust 104.1 mm (4.10 in.)
Minimum overall length Intake 104.1 mm (4.10 in.)
Exhaust 103.8 mm (4.09 in.)
Standard valve face angle 45.5°
Camshaft No. 2 and No. 3 camshaft thrust clearance (for Intake Camshaft) Standard thrust clearance 0.035 to 0.160 mm (0.00138 to 0.00630 in.)
Maximum thrust clearance 0.180 mm (0.00709 in.)
No. 1 and No. 4 camshaft thrust clearance (for Exhaust Camshaft) Standard thrust clearance 0.035 to 0.160 mm (0.00138 to 0.00630 in.)
Maximum thrust clearance 0.180 mm (0.00709 in.)
Maximum runout 0.03 mm (0.00118 in.)
Standard cam lobe height No. 2 and No. 3 camshaft (intake) 37.277 to 37.387 mm (1.468 to 1.472 in.)
No. 1 and No. 4 camshaft (exhaust) 38.324 to 38.434 mm (1.509 to 1.513 in.)
Minimum cam lobe height No. 2 and No. 3 camshaft (intake) 37.277 mm (1.468 in.)
No. 1 and No. 4 camshaft (exhaust) 38.324 mm (1.509 in.)
Standard journal diameter No. 1 journal 29.969 to 29.985 mm (1.180 to 1.181 in.)
Other journal 26.969 to 26.985 mm (1.0618 to 1.0624 in.)
Standard oil clearance 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum oil clearance 0.072 mm (0.00283 in.)
Cylinder head bolt Standard diameter 12.8 to 13.0 mm (0.504 to 0.512 in.)
Minimum diameter 12.5 mm (0.492 in.)
Crankshaft bearing cap bolt Bolt length Item (bolt A) 106 mm (4.17 in.)
Item (bolt B) 90.5 mm (3.56 in.)
Measuring area Item (bolt A) 73 mm (2.87 in.)
Item (bolt B) 63 mm (2.48 in.)
Standard diameter Item (bolt A) 10.8 to 11.0 mm (0.425 to 0.433 in.)
Item (bolt B) 9.8 to 10.0 mm (0.386 to 0.394 in.)
Minimum diameter Item (bolt A) 10.5 mm (0.413 in.)
Item (bolt B) 9.5 mm (0.374 in.)
Cylinder block Cylinder block for flatness Maximum warpage 0.05 mm (0.00197 in.)
Cylinder block tight plug Standard depth 1.7 to 2.7 mm (0.0669 to 0.106 in.)
Cylinder bore Standard diameter 86.000 to 86.013 mm (3.3858 to 3.3863 in.)
Maximum diameter 86.03 mm (3.3870 in.)
Cylinder block main journal bore diameter for No. 1 and No. 3 journals '1' 79.000 to 79.006 mm (3.11023 to 3.11047 in.)
'2' More than 79.006 to 79.012 mm (more than 3.11047 to 3.11070 in.)
'3' More than 79.012 to 79.018 mm (more than 3.11070 to 3.11094 in.)
for No. 2, 4 and 5 journals '1' 79.000 to 79.006 mm (3.11023 to 3.11047 in.)
'2' More than 79.006 to 79.012 mm (more than 3.11047 to 3.11070 in.)
'3' More than 79.012 to 79.018 mm (more than 3.11070 to 3.11094 in.)
Straight pin Standard protrusion Pin ''A'' and ''B''' 5.0 to 7.0 mm (0.197 to 0.275 in.)
Pin 'C' 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin 'D' and 'F' 3.5 to 6.0 mm (0.138 to 0.236 in.)
Pin "E" 4.5 to 7.0 mm (0.177 to 0.276 in.)
Piston Standard piston diameter 85.932 to 85.966 mm (3.383 to 3.384 in.)
Minimum piston diameter 85.910 mm (3.382 in.)
Piston oil clearance Standard oil clearance 0.034 to 0.081 mm (0.00134 to 0.00319 in.)
Maximum oil clearance 0.091 mm (0.00358 in.)
Piston x piston pin Standard piston pin hole inside diameter Mark A 29.009 to 29.013 mm (1.1421 to 1.1422 in.)
Mark B 29.013 to 29.017 mm (1.1422 to 1.1424 in.)
Mark C 29.017 to 29.021 mm (1.1424 to 1.1426 in.)
Standard piston pin diameter

Mark A

(paint color "white")

 29.000 to 29.004 mm (1.1417 to 1.1419 in.)

Mark B

(paint color "pink")

 29.004 to 29.008 mm (1.1419 to 1.1420 in.)

Mark C

(paint color "blue")

 29.008 to 29.012 mm (1.1420 to 1.1422 in.)
Standard oil clearance 0.005 to 0.013 mm (0.000197 to 0.000512 in.)
Maximum oil clearance 0.018 mm (0.000709 in.)
Connecting rod x Piston pin Standard bush inside diameter Mark A 29.019 to 29.023 mm (1.1425 to 1.1426 in.)
Mark B 29.023 to 29.027 mm (1.1426 to 1.1428 in.)
Mark C 29.027 to 29.031 mm (1.1428 to 1.1430 in.)
Standard oil clearance 0.015 to 0.023 mm (0.000591 to 0.000906 in.)
Maximum oil clearance 0.028 mm (0.00110 in.)
Piston ring Standard ring groove clearance No. 1 compression ring 0.11 to 0.15 mm (0.00433 to 0.00591 in.)
No. 2 compression ring 0.08 to 0.12 mm (0.00315 to 0.00472 in.)
Oil ring 0.03 to 0.07 mm (0.00118 to 0.00276 in.)
Standard end gap

No. 1 compression ring

(w/ EGR System)

 0.22 to 0.32 mm (0.00866 to 0.0126 in.)

No. 1 compression ring

(w/o EGR System)

 0.20 to 0.30 mm (0.00787 to 0.0118 in.)
No. 2 compression ring 0.47 to 0.62 mm (0.0185 to 0.0244 in.)
Oil ring 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
Maximum end gap No. 1 compression ring 0.40 mm (0.0157 in.)
No. 2 compression ring 0.75 mm (0.0295 in.)
Oil ring 0.50 mm (0.0197 in.)
Chain No. 1 chain Maximum chain elongation 143.95 mm (5.67 in.)
No. 2 chain Maximum chain elongation 143.95 mm (5.67 in.)
Fuel supply pump shaft sprocket Minimum gear diameter (with chain) No. 1 chain 101.55 mm (4.00 in.)
No. 2 chain 101.55 mm (4.00 in.)
Camshaft timing sprocket Minimum gear diameter (with chain) No. 1 chain 134.90 mm (5.31 in.)
No. 2 chain 134.90 mm (5.31 in.)
No. 1 idle gear shaft and No. 1 idle gear Standard idle gear shaft diameter 44.947 to 44.975 mm (1.770 to 1.771 in.)
Standard idle gear inside diameter 45.000 to 45.025 mm (1.772 to 1.773 in.)
Standard oil clearance 0.025 to 0.078 mm (0.000984 to 0.00307 in.)
Maximum oil clearance 0.078 mm (0.00307 in.)
Chain tensioner slipper Maximum depth No. 1 1.0 mm (0.0394 in.)
No. 2 1.0 mm (0.0394 in.)
Chain vibration damper Maximum depth No. 1 1.0 mm (0.0394 in.)
No. 2 1.0 mm (0.0394 in.)
Intake manifold for flatness Maximum warpage No.1 intake manifold No. 3 intake manifold 0.10 mm (0.00394 in.)
Cylinder head 0.10 mm (0.00394 in.)
No. 2 intake manifold No. 3 intake manifold 0.10 mm (0.00394 in.)
Cylinder head 0.10 mm (0.00394 in.)
No. 3 intake manifold Intake pipe 0.10 mm (0.00394 in.)
No. 2 and No. 3 intake manifold 0.15 mm (0.00591 in.)
Exhaust manifold for flatness Maximum warpage 0.80 mm (0.0315 in.)
CYLINDER HEAD
Cylinder head Valve seat Standard width Intake 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Valve guide bush Standard bush bore diameter (for cylinder head) 10.985 to 11.006 mm (0.432 to 0.433 in.)
Standard valve guide bush diameter STD 11.033 to 11.044 mm (0.434 to 0.435 in.)
O/S 0.05 11.083 to 11.094 mm (0.436 to 0.437 in.)
Standard protrusion height 9.0 to 9.4 mm (0.354 to 0.370 in.)
Standard overall length 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.)
Ring pin Standard protrusion 4.4 to 5.6 mm (0.173 to 0.220 in.)
Valve stem oil seal Standard protrusion height Below 14.7 mm (0.579 in.)
CYLINDER BLOCK
Connecting rod Standard thrust clearance 0.14 to 0.54 mm (0.00551 to 0.0213 in.)
Maximum thrust clearance 0.60 mm (0.0236 in.)
Crankshaft Standard thrust clearance 0.02 to 0.22 mm (0.000787 to 0.00866 in.)
Maximum thrust clearance 0.30 mm (0.0118 in.)
Standard thrust washer thickness 2.44 to 2.49 mm (0.0960 to 0.0980 in.)