SERVICING SPECIFICATIONS (1) ENGINE BODY

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1 SERVICING SPECIFICATIONS (1) ENGINE BODY Lubricating oil capacity Oil pan depth 110 mm (4.33 in.) 5.7 L 1.5 U.S.gals (1/14) Oil pan depth 125 mm (4.92 in.) 5.1 L 1.3 U.S.gals Oil pan depth 130 mm (5.12 in.) 6.7 L 1.8 U.S.gals Cylinder head surface Flatness 0.05 mm in. Compression pressure 3.73 to 4.11 MPa 38.0 to 42.0 kgf/cm to 597 psi 2.26 MPa 23.0 kgf/cm psi 3.14 to 3.53 MPa 32.0 to 36.0 kgf/cm to 512 psi 2.26 MPa 23.0 kgf/cm psi Top clearance 0.55 to 0.70 mm to in to 1.0 mm to in.

2 (2/14) Valve clearance (When cold) to mm to in. Valve & valve seat (B) (A) Valve stem to valve guide (C) Face angle (A) (Intake) Face angle (A) (Exhaust) Seat angle (B) (Intake) Seat angle (B) (Exhaust) Seat width (C) (Intake) Seat width (C) (Exhaust) 1.0 rad rad rad rad mm in mm in to mm to in mm in. Valve stem to mm to in. Valve guide to mm to in. Valve recessing mm (Protrusion) to 0.25 mm (Recessing) in. (Protrusion) to in. (Recessing) 0.40 mm (Recessing) in. (Recessing) Valve spring (A) Tilt (A) 1.0 mm in. (B) Free length (B) 37.0 to 37.5 mm 1.46 to 1.47 in mm 1.44 in. Setting load / Setting length N / 31.0 mm kgf / 31.0 mm lbf / 1.22 in N / 31.0 mm kgf / 31.0 mm lbf / 1.22 in.

3 (3/14) Valve timing T.D.C Ė.C. I.O. Open (Intake valve) 0.24 rad before T.D.C. 14 before T.D.C rad before T.D.C. 22 before T.D.C. I.C. B.D.C. E.O. Close (Intake valve) 0.52 rad after B.D.C. 30 after B.D.C rad after B.D.C. 47 after B.D.C. Open (Exhaust valve) 0.96 rad before B.D.C. 55 before B.D.C rad before B.D.C. 52 before B.D.C. Close (Exhaust valve) 0.24 rad after T.D.C. 14 after T.D.C rad after T.D.C. 17 after T.D.C. Rocker arm shaft to rocker arm to mm to in mm in. Rocker arm shaft to mm to in. Rocker arm to mm to in. Push rod Alignment 0.25 mm in. Tappet to tappet guide to mm to in mm in. Tappet to mm to in. Tappet guide to mm to in.

4 (4/14) Timing gear Backlash (Crank gear to idle gear 1) to mm to in. Backlash (Idle gear 1 to cam gear) to mm to in. Backlash (Idle gear 1 to injection pump) to mm to in. Backlash (Injection pump gear to governor gear) to mm to in. Backlash (Idle gear 1 to idle gear 2) Equipped with idle gear to mm to in. Backlash (Idle gear 2 to governor gear) Equipped with idle gear to mm to in. Idle gear Side clearance (Idle gear 1) 0.20 to 0.51 mm to in mm in. Side clearance (Idle gear 2) Equipped with idle gear to 0.51 mm to in mm in. Idle gear shaft 1 to idle gear bushing to mm to in mm in. Idle gear shaft to mm to in. Idle gear bushing to mm to in. Idle gear shaft 2 to idle gear bushing to mm to in mm in. Idle gear shaft to mm to in. Idle gear bushing to mm to in. Camshaft Alignment 0.01 mm in.

5 (5/14) Camshaft Side clearance to 0.22 mm to in mm in. Cam Height (Intake) mm in mm in. Height (Exhaust) mm in mm in. Camshaft journal to cylinder block bore Oil clearance to mm to in. Camshaft journal to mm to in. Cylinder block bore to mm to in. Piston pin bore Piston pin bore to mm to in mm in. Piston pin to small end bushing to mm to in. Piston pin to mm to in. Small end bushing to mm to in.

6 (6/14) Piston ring 0.30 to 0.45 mm to in mm in. Ring gap (Top ring) 0.20 to 0.35 mm to in mm in. Ring gap (Second ring) 0.30 to 0.45 mm to in to 0.55 mm to in mm in mm in to 0.40 mm to in mm in. Ring gap (Oil ring) 0.30 to 0.55 mm to in mm in. Piston ring groove to piston ring to mm to in. 0.2 mm in. (Second ring) to mm to in. 0.2 mm in to mm to in. (Oil ring) to mm to in in. Connecting rod Alignment 0.05 mm in. Crankshaft Alignment 0.02 mm in.

7 (7/14) Crankshaft journal to crankshaft bearing 1 Oil clearance Crankshaft journal Crankshaft bearing to mm to in to mm to in to mm to in mm in. Oil clearance to mm to in mm in. Crankshaft journal to mm to in. Crankshaft bearing to mm to in. Crankshaft journal to crankshaft bearing 2 Oil clearance Crankshaft journal Crankshaft bearing to mm to in to mm to in to mm to in mm in. Oil clearance to mm to in mm in. Crankshaft journal to mm to in. Crankshaft bearing to mm to in. Crankshaft journal to crankshaft bearing 3 Oil clearance to mm to in mm in. Crankshaft journal to mm to in. Crankshaft bearing to mm to in.

8 (8/14) Crankpin to crankpin bearing Oil clearance to mm to in mm in. Crankpin to mm to in. Crankpin bearing to mm to in. Crankshaft Side clearance 0.15 to 0.31 mm to in mm in. Cylinder to mm to in mm in. Bore (Standard size) to mm to in mm in to mm to in mm in. Bore (Oversize) to mm to in mm in.

9 (2) LUBRICATING SYSTEM Engine oil pressure Engine oil pressure (At idle speed) 49 kpa 0.50 kgf/cm psi (9/14) Engine oil pressure (At rated speed) 197 to 441 kpa 2.00 to 4.50 kgf/cm to 64.0 psi 147 kpa 1.50 kgf/cm psi Inner rotor to outer rotor (Oil pump) to 0.18 mm to in. Outer rotor to pump body (Oil pump) to mm to in. Inner rotor to cover (Oil pump) to mm to in.

10 (3) COOLING SYSTEM Fan belt (10/14) Tension 7.0 to 9.0 mm (0.28 to 0.35 in.) deflection at 98 N (10 kgf, 22 lbf) of force Thermostat Valve opening temperature (At beginning) 69.5 to 72.5 C to F Valve opening temperature (Opened completely) 85 C 185 F Radiator Water tightness No leak at specified pressure Radiator cap Pressure falling time 10 seconds or more for pressure falling kpa ( kgf/cm 2, psi)

11 (4) FUEL SYSTEM Injection pump Rated revolution : 3000 min -1 (rpm) D1005-E3B D1105-E3B D1305-E3B V1505-E3B to rad before T.D.C to before T.D.C to rad before T.D.C to before T.D.C. (11/14) Injection timing Rated revolution : 3600 min -1 (rpm) D1105-E3B V1505-E3B to rad before T.D.C to before T.D.C. Rated revolution : 1800 min -1 (rpm) D1005-E3BG D1105-E3BG D1305-E3BG V1505-E3BG to rad before T.D.C to before T.D.C to rad before T.D.C to before T.D.C. Pump element Fuel Tightness MPa kgf/cm psi Delivery valve Fuel Tightness 10 seconds MPa kgf/cm psi 5 seconds MPa kgf/cm psi Injection nozzle Injection pressure to MPa to kgf/cm to 2133 psi Injection nozzle Valve seat tightness No fuel leak at MPa kgf/cm psi

12 (12/14) (5) ELECTRICAL SYSTEM Starter (Gear Reduction Type) Commutator 30.0 mm 1.18 in 29.0 mm 1.14 in. Starter (Electromagnetic Drive Type) Commutator 28.0 mm 1.10 in 27.0 mm 1.06 in. Starter Mica under cut 0.50 to 0.80 mm to in mm in. Starter Brush length 16.0 mm in mm in. Starter Brush holder resistance (Brush holder - Holder support) Infinity Starter Field coil resistance (Lead - Brush) Continuity

13 (13/14) Starter Field coil resistance (Brush - Yoke) Infinity Starter Armature coil resistance (Commutator - Armature coil core) Infinity Starter Armature coil resistance (Segment - Segment) Continuity Alternator Stator resistance Less than 1.0 Alternator Rotor resistance 2.9 Alternator Slip ring 14.4 mm in mm in.

14 (14/14) Alternator Brush length 10.0 mm in. 8.4 mm 0.33 in. Glow plug Resistance Approx. 0.9 Stop solenoid Pulling Coil Resistance (Terminal 1 - body) Approx Holding Coil Resistance (Terminal 2 - body) Approx. 16

15 TIGHTENING TORQUES (1) Special Tightening Torques For " * " marked screws, bolts and nuts on under table, apply engine oil to their threads and seats before tightening. Cylinder head cover nut Cylinder head cover nut Main bearing case screw 1 * (1/3) 7 to 8 N m 0.7 to 0.9 kgf m 5 to 6 lbf ft 9.81 to 11.2 N m 1.00 to 1.15 kgf m 7.24 to 8.31 lbf ft 30 to 34 N m 3.0 to 3.5 kgf m 22 to 25 lbf ft Main bearing case screw 2 * Cylinder head screw Flywheel screw * 49 to 53 N m 5.0 to 5.5 kgf m 37 to 39 lbf ft 64 to 68 N m 6.5 to 7.0 kgf m 47 to 50 lbf ft 54 to 58 N m 5.5 to 6.0 kgf m 40 to 43 lbf ft Cylinder head tightening order Connecting rod screw * (A) 3 cylinder model (B) 4 cylinder model n j b g n f c k f c k r j b g o m e d i a h l q i a h m e d l p (A) 3 cylinder model a n (B) 4 cylinder model a r 42 to 46 N m 4.2 to 4.7 kgf m 31 to 33 lbf ft

16 (2/3) Rocker arm bracket nut * Rocker arm bracket screw * Idle gear shaft screw * 22 to 26 N m 2.2 to 2.7 kgf m 16 to 19 lbf ft 22 to 26 N m 2.2 to 2.7 kgf m 16 to 19 lbf ft 9.81 to 11.2 N m 1.00 to 1.15 kgf m 7.24 to 8.31 lbf ft Bearing case cover mounting screw Fan drive pulley screw * Glow plug 9.81 to 11.2 N m 1.00 to 1.15 kgf m 7.24 to 8.31 lbf ft 236 to 245 N m 24.0 to 25.0 kgf m 174 to 180 lbf ft 7.9 to 14 N m 0.80 to 1.5 kgf m 5.8 to 10 lbf ft Nozzle holder assembly Oil pressure switch Injection pipe retaining nut 49 to 68 N m 5.0 to 7.0 kgf m 37 to 50 lbf ft 15 to 19 N m 1.5 to 2.0 kgf m 11 to 14 lbf ft 25 to 34 N m 2.5 to 3.5 kgf m 18 to 25 lbf ft

17 (3/3) Overflow pipe assembly retaining nut Starter (B terminal nut) Alternator pulley nut 20 to 24 N m 2.0 to 2.5 kgf m 15 to 18 lbf ft 5.88 to 11.8 N m to 1.20 kgf m 4.34 to 8.70 lbf ft 58.4 to 78.9 N m 5.95 to 8.05 kgf m 43.1 to 58.2 lbf ft Drain plug with copper gasket Drain plug with rubber coated gasket 33 to 37 N m 3.3 to 3.8 kgf m 24 to 27 lbf ft 45 to 53 N m 4.5 to 5.5 kgf m 33 to 39 lbf ft (2) General Tightening Torques Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be sure to check out the numbers as shown below. None or 4 : Standard grade 7 : Special grade Nominal Diameter M6 M8 M10 M12 Standard Grade 7.9 to 9.3 N m 0.80 to 0.95 kgf m 5.8 to 6.8 lbf ft 18 to 20 N m 1.8 to 2.1 kgf m 13 to 15 lbf ft 40 to 45 N m 4.0 to 4.6 kgf m 29 to 33 lbf ft 63 to 72 N m 6.4 to 7.4 kgf m 47 to 53 lbf ft Special Grade 9.81 to 11.2 N m 1.00 to 1.15 kgf m 7.24 to 8.31 lbf ft 24 to 27 N m 2.4 to 2.8 kgf m 18 to 20 lbf ft 48 to 55 N m 4.9 to 5.7 kgf m 36 to 41 lbf ft 78 to 90 N m 7.9 to 9.2 kgf m 58 to 66 lbf ft

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