1ND-TV ENGINE MECHANICAL SERVICE DATA

Table 1. ENGINE

Engine speed

Standard idle speed

720 to 820 rpm

Maximum speed

5150 to 5250 rpm

Compression (w/ Glow Plug Controller)

Standard

2300 kPa (23.5 kgf/cm2, 334 psi)

Minimum

2050 kPa (20.9 kgf/cm2, 297 psi)

Difference between each cylinder

500 kPa (5.1 kgf/cm2, 73 psi)

Compression (w/o Glow Plug Controller)

Standard

2300 kPa (23.5 kgf/cm2, 334 psi)

Minimum

2050 kPa (20.9 kgf/cm2, 297 psi)

Difference between each cylinder

500 kPa (5.1 kgf/cm2, 73 psi)
Table 2. VALVE CLEARANCE (w/ Glow Plug Controller)

Valve clearance

Standard

Cold

Intake

0.11 to 0.17 mm (0.00433 to 0.00669 in.)

Exhaust

0.14 to 0.20 mm (0.00551 to 0.00787 in.)
Table 3. VALVE CLEARANCE (w/o Glow Plug Controller)

Valve clearance

Standard

Cold

Intake

0.11 to 0.17 mm (0.00433 to 0.00669 in.)

Exhaust

0.14 to 0.20 mm (0.00551 to 0.00787 in.)
Table 4. FRONT CRANKSHAFT OIL SEAL (w/ Glow Plug Controller)

Timing chain cover oil seal

Depth

-0.6 to 0 mm (-0.0236 to 0 in.)

Compression spring

(for Front exhaust pipe assembly)

Free length

Maximum

Front

41.5 mm (1.63 in.)
Table 5. FRONT CRANKSHAFT OIL SEAL (w/o Glow Plug Controller)

Timing chain cover oil seal

Depth

-0.6 to 0 mm (-0.0236 to 0 in.)

Compression spring

(for Front exhaust pipe assembly)

Free length

Maximum

Front

41.5 mm (1.63 in.)
Table 6. REAR CRANKSHAFT OIL SEAL

ENGINE REAR OIL SEAL

Depth

-1.0 to 0 mm (-0.0394 to 0 in.)
Table 7. ENGINE UNIT (w/ Glow Plug Controller)

Chain sub-assembly

Length

Maximum

156.5 mm (6.16 in.)

No. 2 chain sub-assembly

Length

Maximum

115.2 mm (4.54 in.)

Camshaft timing sprocket

Diameter

Minimum

w/ chain

134.8 mm (5.31 in.)

Crankshaft timing sprocket

Diameter

Minimum

w/ chain

71.51 mm (2.82 in.)

Oil pump drive gear

Diameter

Minimum

w/ chain

56.4 mm (2.22 in.)

Oil pump drive shaft gear

Diameter

Minimum

w/ chain

58.6 mm (2.31 in.)

Chain tensioner slipper

Wear

Maximum

1.0 mm (0.0394 in.)

No. 1 chain vibration damper

Wear

Maximum

1.0 mm (0.0394 in.)

Chain tensioner plate

Wear

Maximum

1.0 mm (0.0394 in.)

Camshaft

Runout

Maximum

0.03 mm (0.00118 in.)

Cam lobe height

Standard

Intake

34.484 to 34.584 mm (1.3576 to 1.3616 in.)

Exhaust

35.299 to 35.399 mm (1.3897 to 1.3937 in.)

Minimum

Intake

34.434 mm (1.3557 in.)

Exhaust

35.249 mm (1.3878 in.)

Cam journal diameter

23.979 to 23.995 mm (0.9441 to 0.9447 in.)

Cylinder head set bolt

Diameter

Standard

11.5 to 12.0 mm (0.453 to 0.472 in.)

Minimum

11.2 mm (0.441 in.)
Table 8. ENGINE UNIT (w/o Glow Plug Controller)

Chain sub-assembly

Length

Maximum

156.5 mm (6.161 in.)

No. 2 chain sub-assembly

Length

Maximum

116.5 mm (4.586 in.)

Camshaft timing sprocket

Diameter

Minimum

w/ chain

132.5 mm (5.216 in.)

Crankshaft timing sprocket

Diameter

Minimum

w/ chain

69.0 mm (2.716 in.)

Oil pump drive gear

Diameter

Minimum

w/ chain

57.6 mm (2.267 in.)

Oil pump drive shaft gear

Diameter

Minimum

w/ chain

53.5 mm (2.106 in.)

Chain tensioner slipper

Wear

Maximum

1.0 mm (0.0394 in.)

No. 1 chain vibration damper

Wear

Maximum

1.0 mm (0.0394 in.)

Chain tensioner plate

Wear

Maximum

1.0 mm (0.0394 in.)

Camshaft

Runout

Maximum

0.03 mm (0.00118 in.)

Cam lobe height

Standard

Intake

34.484 to 34.584 mm (1.3576 to 1.3616 in.)

Exhaust

34.773 to 34.873 mm (1.3690 to 1.3730 in.)

Minimum

Intake

34.064 mm (1.3411 in.)

Exhaust

34.353 mm (1.3525 in.)

Cam journal diameter

23.979 to 23.995 mm (0.9441 to 0.9447 in.)

Cylinder head set bolt

Diameter

Standard

11.5 to 12.0 mm (0.453 to 0.472 in.)

Minimum

11.2 mm (0.441 in.)

Exhaust manifold

Warpage

Maximum

0.7 mm (0.0276 in.)
Table 9. CYLINDER HEAD (w/ Glow Plug Controller)

Cylinder head sub-assembly

Warpage

Maximum

Cylinder block sub-assembly side

0.08 mm (0.0315 in.)

Intake manifold side

0.20 mm (0.00787 in.)

Exhaust manifold side

0.20 mm (0.00787 in.)

Valve seat

Width

Standard

Intake

1.0 to 1.4 mm (0.0394 to 0.0551 in.)

Exhaust

1.2 to 1.6 mm (0.0472 to 0.0630 in.)

Camshaft oil clearance

Clearance

Standard

0.037 to 0.073 mm (0.00146 to 0.00287 in.)

Maximum

0.10 mm (0.00394 in.)

Camshaft thrust clearance

Clearance

Standard

0.040 to 0.090 mm (0.00157 to 0.00354 in.)

Maximum

0.25 mm (0.00984 in.)

Intake valve

Overall length

Standard

99.69 to 100.29 mm (3.9248 to 3.9484 in.)

Maximum

99.19 mm (3.9051 in.)

Stem diameter

Standard

5.970 to 5.985 mm (0.2350 to 0.2356 in.)

Margin thickness

Standard

1.2 mm (0.0472 in.)

Minimum

0.6 mm (0.0236 in.)

Exhaust valve

Overall length

Standard

99.39 to 99.99 mm (3.9130 to 3.9366 in.)

Maximum

98.89 mm (3.8933 in.)

Stem diameter

Standard

5.965 to 5.980 mm (0.2348 to 0.2354 in.)

Margin thickness

Standard

1.5 mm (0.0591 in.)

Minimum

0.7 mm (0.0276 in.)

Outer compression spring

Length

Standard

42.80 mm (1.69 in.)

Deviation

1.5 mm (0.0591 in.)

Valve guide bush

Inside diameter

Standard

6.010 to 6.030 mm (0.2367 to 0.2374 in.)

Oil clearance

Standard

Intake

0.025 to 0.060 mm (0.000984 to 0.00236 in.)

Exhaust

0.030 to 0.065 mm (0.00118 to 0.00256 in.)

Minimum

Intake

0.08 mm (0.00315 in.)

Exhaust

0.10 mm (0.00394 in.)

Bore diameter

Standard

10.985 to 11.006 mm (0.4325 to 0.4333 in.)

Protrusion height

Standard

Intake

15.9 to 16.7 mm (0.626 to 0.657 in.)

Exhaust

15.9 to 16.7 mm (0.626 to 0.657 in.)

Ring pin

Protrusion height

(A)

3.5 mm (0.138 in.)

(B)

4.0 to 5.0 mm (0.157 to 0.197 in.)

Straight pin

Protrusion height

Standard

18.5 to 19.5 mm (0.728 to 0.768 in.)

Intake valve seat

Width

Standard

1.0 to 1.4 mm (0.0394 to 0.0551 in.)

Exhaust valve seat

Width

Standard

1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Table 10. CYLINDER HEAD (w/o Glow Plug Controller)

Cylinder head sub-assembly

Warpage

Maximum

Cylinder block sub-assembly side

0.08 mm (0.0315 in.)

Intake manifold side

0.20 mm (0.00787 in.)

Exhaust manifold side

0.20 mm (0.00787 in.)

Valve seat

Width

Standard

Intake

1.0 to 1.2 mm (0.0394 to 0.0472 in.)

Exhaust

1.2 to 1.6 mm (0.0472 to 0.0630 in.)

Camshaft oil clearance

Clearance

Standard

0.037 to 0.073 mm (0.00146 to 0.00287 in.)

Maximum

0.10 mm (0.00394 in.)

Camshaft thrust clearance

Clearance

Standard

0.080 to 0.180 mm (0.00315 to 0.00709 in.)

Maximum

0.25 mm (0.00984 in.)

Intake valve

Overall length

Standard

99.69 to 100.29 mm (3.9248 to 3.9484 in.)

Maximum

99.19 mm (3.9051 in.)

Stem diameter

Standard

5.970 to 5.985 mm (0.2350 to 0.2356 in.)

Margin thickness

Standard

1.2 mm (0.0472 in.)

Minimum

0.6 mm (0.0236 in.)

Exhaust valve

Overall length

Standard

99.39 to 99.99 mm (3.9130 to 3.9366 in.)

Maximum

98.89 mm (3.8933 in.)

Stem diameter

Standard

5.965 to 5.980 mm (0.2348 to 0.2354 in.)

Margin thickness

Standard

1.5 mm (0.0591 in.)

Minimum

0.7 mm (0.0276 in.)

Outer compression spring

Length

Standard

42.17 mm (1.6602 in.)

Deviation

1.5 mm (0.0591 in.)

Valve guide bush

Inside diameter

Standard

6.010 to 6.030 mm (0.2367 to 0.2374 in.)

Oil clearance

Standard

Intake

0.025 to 0.060 mm (0.000984 to 0.00236 in.)

Exhaust

0.030 to 0.065 mm (0.00118 to 0.00256 in.)

Minimum

Intake

0.08 mm (0.00315 in.)

Exhaust

0.10 mm (0.00394 in.)

Bore diameter

Standard

10.985 to 11.006 mm (0.4325 to 0.4333 in.)

Protrusion height

Standard

Intake

15.9 to 16.7 mm (0.626 to 0.657 in.)

Exhaust

Ring pin

Protrusion height

(A)

3.5 mm (0.138 in.)

(B)

4.0 to 5.0 mm (0.157 to 0.197 in.)

Straight pin

Protrusion height

Standard

18.5 to 19.5 mm (0.728 to 0.768 in.)

Intake valve seat

Width

Standard

1.0 to 1.2 mm (0.0394 to 0.0472 in.)

Exhaust valve seat

Width

Standard

1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Table 11. CYLINDER BLOCK (w/ Glow Plug Controller)

Connecting rod

Thrust clearance

Standard

0.16 to 0.36 mm (0.00630 to 0.0142 in.)

Maximum

0.36 mm (0.0142 in.)

Oil clearance

Standard

0.014 to 0.038 mm (0.000551 to 0.00150 in.)

Maximum

0.065 mm (0.00256 in.)

Thrust clearance

Standard

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum

0.30 mm (0.0118 in.)

Diameter

1

47.000 to 47.008 mm (1.85039 to 1.85071 in.)

2

47.009 to 47.016 mm (1.85074 to 1.85102 in.)

3

47.017 to 47.024 mm (1.85106 to 1.85133 in.)

Center bearing thickness

1

1.489 to 1.493 mm (0.05862 to 0.05878 in.)

2

1.494 to 1.497 mm (0.05882 to 0.5894 in.)

3

1.498 to 1.501 mm (0.05898 to 0.05909 in.)

Inside diameter

Standard

Mark (A)

27.022 to 27.026 mm (1.06386 to 1.06401 in.)

Mark (B)

27.027 to 27.030 mm (1.06405 to 1.06417 in.)

Mark (C)

27.031 to 27.034 mm (1.06421 to 1.06433 in.)

Misalignment

Maximum

0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

Twist

0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

Thrust washer thickness

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Cylinder block

Warpage

Maximum

0.05 mm (0.00197 in.)

Cylinder bore

Diameter

Standard

73.000 to 73.013 mm (2.8740 to 2.8745 in.)

Maximum

73.13 mm (2.8791 in.)

Piston

Diameter

Standard

72.936 to 73.000 mm (2.8715 to 2.8740 in.)

Oil clearance

Standard

0.050 to 0.077 mm (0.000197 to 0.00303 in.)

Maximum

0.08 mm (0.00315 in.)

Piston pin hole

Diameter

Standard

Mark (A)

27.019 to 27.023 mm (1.06374 to 1.06390 in.)

Mark (B)

27.023 to 27.027 mm (1.06390 to 1.06405 in.)

Mark (C)

27.027 to 27.031 mm (1.06405 to 1.06421 in.)

Piston pin

Oil clearance

Standard

0.007 to 0.015 mm (0.0003 to 0.0006 in.)

Maximum

0.05 mm (0.0020 in.)

Diameter

Standard

Mark (A)

27.008 to 27.012 mm (1.06330 to 1.06346 in.)

Mark (B)

27.013 to 27.016 mm (1.06350 to 1.06362 in.)

Mark (C)

27.017 to 27.020 mm (1.06366 to 1.06378 in.)

Piston ring

Groove clearance

Standard

No. 1 compression ring

0.110 to 0.150 mm (0.00433 to 0.00591 in.)

No. 2 compression ring

0.075 to 0.110 mm (0.00295 to 0.00433 in.)

Oil ring

0.030 to 0.070 mm (0.00118 to 0.00276 in.)

End gap

Standard

No. 1 compression ring

0.17 to 0.27 mm (0.00669 to 0.0106 in.)

No. 2 compression ring

0.61 to 0.71 mm (0.0240 to 0.0280 in.)

Oil ring

0.20 to 0.40 mm (0.00787 to 0.0157 in.)

Maximum

No. 1 compression ring

0.42 mm (0.0165 in.)

No. 2 compression ring

0.80 mm (0.0315 in.)

Oil ring

0.70 mm (0.0276 in.)

Connecting rod bolt

Diameter

Standard

6.6 to 6.7 mm (0.260 to 0.264 in.)

Minimum

6.4 mm (0.252 in.)

Crankshaft

Runout

Maximum

0.015 mm (0.000591 in.)

Diameter

Standard

Main journal

45.988 to 46.000 mm (1.8104 to 1.8110 in.)

Taper and out-of-round

Maximum

0.02 mm (0.000787 in.)

Diameter

Standard

Crank pin

43.992 to 44.000 mm (1.7320 to 1.7323 in.)

Taper and out-of-round

Maximum

0.02 mm (0.000787 in.)

Oil clearance

Standard

0.010 to 0.023 mm (0.000394 to 0.000906 in.)

Maximum

0.07 mm (0.00276 in.)

Thrust clearance

Standard

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum

0.30 mm (0.0118 in.)

Upper crankshaft thrust washer thickness

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Crankshaft bearing cap set bolt

Diameter

Standard

10.8 to 11.0 mm (0.425 to 0.433 in.)

Minimum

10.6 mm (0.417 in.)

Cylinder block main journal bore diameter

Mark 0

50.000 to 50.002 mm (1.96850 to 1.96858 in.)

Mark 1

50.003 to 50.004 mm (1.96862 to 1.96866 in.)

Mark 2

50.005 to 50.006 mm (1.96870 to 1.96874 in.)

Mark 3

50.007 to 50.009 mm (1.96878 to 1.96885 in.)

Mark 4

50.010 to 50.011 mm (1.96889 to 1.96893 in.)

Mark 5

50.012 to 50.013 mm (1.96897 to 1.96901 in.)

Mark 6

50.014 to 50.016 mm (1.96905 to 1.96913 in.)

Crank Main Journal Diameter

Mark 0

45.999 to 46.000 mm (1.81098 to 1.81102 in.)

Mark 1

45.997 to 45.998 mm (1.81090 to 1.81094 in.)

Mark 2

45.995 to 45.996 mm (1.81082 to 1.81086 in.)

Mark 3

45.993 to 45.994 mm (1.81074 to 1.81078 in.)

Mark 4

45.991 to 45.992 mm (1.81067 to 1.81071 in.)

Mark 5

45.989 to 45.990 mm (1.81059 to 1.81063 in.)

Crankshaft main bearing thickness

Mark 1

1.992 to 1.995 mm (0.07843 to 0.07854 in.)

Mark 2

1.996 to 1.998 mm (0.07858 to 0.07866 in.)

Mark 3

1.999 to 2.001 mm (0.07870 to 0.07878 in.)

Mark 4

2.002 to 2.004 mm (0.07882 to 0.07890 in.)
Table 12. CYLINDER BLOCK (w/o Glow Plug Controller)

Connecting rod

Thrust clearance

Standard

0.16 to 0.36 mm (0.00630 to 0.0142 in.)

Maximum

0.36 mm (0.0142 in.)

Oil clearance

Standard

0.014 to 0.038 mm (0.000551 to 0.00150 in.)

Maximum

0.065 mm (0.00256 in.)

Thrust clearance

Standard

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum

0.30 mm (0.0118 in.)

Diameter

1

47.000 to 47.008 mm (1.85039 to 1.85071 in.)

2

47.009 to 47.016 mm (1.85074 to 1.85102 in.)

3

47.017 to 47.024 mm (1.85106 to 1.85133 in.)

Center bearing thickness

1

1.489 to 1.493 mm (0.05862 to 0.05878 in.)

2

1.494 to 1.497 mm (0.05882 to 0.5894 in.)

3

1.498 to 1.501 mm (0.05898 to 0.05909 in.)

Inside diameter

Standard

Mark (A)

27.022 to 27.026 mm (1.06386 to 1.06401 in.)

Mark (B)

27.027 to 27.030 mm (1.06405 to 1.06417 in.)

Mark (C)

27.031 to 27.034 mm (1.06421 to 1.06433 in.)

Misalignment

Maximum

0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

Twist

0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

Thrust washer thickness

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Cylinder block

Warpage

Maximum

0.05 mm (0.00197 in.)

Cylinder bore

Diameter

Standard

73.000 to 73.013 mm (2.8740 to 2.8745 in.)

Maximum

73.13 mm (2.8791 in.)

Piston

Diameter

Standard

72.936 to 73.000 mm (2.8715 to 2.8740 in.)

Oil clearance

Standard

0.050 to 0.077 mm (0.000197 to 0.00303 in.)

Maximum

0.08 mm (0.00315 in.)

Piston pin hole

Diameter

Standard

Mark (A)

27.019 to 27.023 mm (1.06374 to 1.06390 in.)

Mark (B)

27.023 to 27.027 mm (1.06390 to 1.06405 in.)

Mark (C)

27.027 to 27.031 mm (1.06405 to 1.06421 in.)

Piston pin

Oil clearance

Standard

0.007 to 0.015 mm (0.0003 to 0.0006 in.)

Maximum

0.05 mm (0.0020 in.)

Diameter

Standard

Mark (A)

27.008 to 27.012 mm (1.06330 to 1.06346 in.)

Mark (B)

27.013 to 27.016 mm (1.06350 to 1.06362 in.)

Mark (C)

27.017 to 27.020 mm (1.06366 to 1.06378 in.)

Piston ring

Groove clearance

Standard

No. 1 compression ring

0.110 to 0.150 mm (0.00433 to 0.00591 in.)

No. 2 compression ring

0.075 to 0.110 mm (0.00295 to 0.00433 in.)

Oil ring

0.030 to 0.070 mm (0.00118 to 0.00276 in.)

End gap

Standard

No. 1 compression ring

0.17 to 0.27 mm (0.00669 to 0.0106 in.)

No. 2 compression ring

0.61 to 0.71 mm (0.0240 to 0.0280 in.)

Oil ring

0.20 to 0.40 mm (0.00787 to 0.0157 in.)

Maximum

No. 1 compression ring

0.42 mm (0.0165 in.)

No. 2 compression ring

0.80 mm (0.0315 in.)

Oil ring

0.70 mm (0.0276 in.)

Connecting rod bolt

Diameter

Standard

6.6 to 6.7 mm (0.260 to 0.264 in.)

Minimum

6.4 mm (0.252 in.)

Crankshaft

Runout

Maximum

0.015 mm (0.000591 in.)

Diameter

Standard

Main journal

45.988 to 46.000 mm (1.8104 to 1.8110 in.)

Taper and out-of-round

Maximum

0.02 mm (0.000787 in.)

Diameter

Standard

Crank pin

43.992 to 44.000 mm (1.7320 to 1.7323 in.)

Taper and out-of-round

Maximum

0.02 mm (0.000787 in.)

Oil clearance

Standard

0.010 to 0.023 mm (0.000394 to 0.000906 in.)

Maximum

0.07 mm (0.00276 in.)

Thrust clearance

Standard

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum

0.30 mm (0.0118 in.)

Upper crankshaft thrust washer thickness

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Crankshaft bearing cap set bolt

Diameter

Standard

10.8 to 11.0 mm (0.425 to 0.433 in.)

Minimum

10.6 mm (0.417 in.)

Cylinder block main journal bore diameter

Mark 0

50.000 to 50.002 mm (1.96850 to 1.96858 in.)

Mark 1

50.003 to 50.004 mm (1.96862 to 1.96866 in.)

Mark 2

50.005 to 50.006 mm (1.96870 to 1.96874 in.)

Mark 3

50.007 to 50.009 mm (1.96878 to 1.96885 in.)

Mark 4

50.010 to 50.011 mm (1.96889 to 1.96893 in.)

Mark 5

50.012 to 50.013 mm (1.96897 to 1.96901 in.)

Mark 6

50.014 to 50.016 mm (1.96905 to 1.96913 in.)

Crank Main Journal Diameter

Mark 0

45.999 to 46.000 mm (1.81098 to 1.81102 in.)

Mark 1

45.997 to 45.998 mm (1.81090 to 1.81094 in.)

Mark 2

45.995 to 45.996 mm (1.81082 to 1.81086 in.)

Mark 3

45.993 to 45.994 mm (1.81074 to 1.81078 in.)

Mark 4

45.991 to 45.992 mm (1.81067 to 1.81071 in.)

Mark 5

45.989 to 45.990 mm (1.81059 to 1.81063 in.)

Crankshaft main bearing thickness

Mark 1

1.992 to 1.995 mm (0.07843 to 0.07854 in.)

Mark 2

1.996 to 1.998 mm (0.07858 to 0.07866 in.)

Mark 3

1.999 to 2.001 mm (0.07870 to 0.07878 in.)

Mark 4

2.002 to 2.004 mm (0.07882 to 0.07890 in.)