SERVICING SPECIFICATIONS (1) ENGINE BODY

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Brittany Webster
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1 SERVICING SPECIFICATIONS (1) ENGINE BODY (1/14) Lubricating oil capacity Cylinder head surface Oil pan depth 121 mm (4.76 in.) Oil pan depth 101 mm (3.98 in.) 2.5 L 0.66 U.S.gals lmp.gals. 3.8 L 1.0 U.S.gals lmp.gals. 3.1 L 0.82 U.S.gals lmp.gals. 2.1 L 0.55 U.S.gals lmp.gals. 2.5 L 0.66 U.S.gals lmp.gals. 3.2 L 0.85 U.S.gals lmp.gals. 3.7 L 0.98 U.S.gals lmp.gals. Flatness 0.05 mm / 500 mm in. / in. Compression pressure 2.84 to 3.24 MPa 29.0 to 33.0 kgf/cm to 469 psi 2.26 MPa 23.0 kgf/cm psi 3.53 to 4.02 MPa 36.0 to 41.0 kgf/cm to 583 psi 2.55 MPa 26.0 kgf/cm psi Top clearance 0.50 to 0.70 mm to in.

2 (2/14) Valve clearance (When cold) to mm to in. Valve & valve seat Face angle (A) rad. 45 B A C Seat angle (B) Seat width (C) rad mm in. Valve stem to valve guide Clearance to mm to in. 0.1 mm in. Valve stem O.D to mm to in. Valve guide I.D to mm to in. Valve recessing mm (Protrusion) to 0.10 mm (Recessing) in. (Protrusion) to in. (Recessing) 0.3 mm (Recessing) in. (Recessing) Valve spring B Free length (A) 31.3 to 31.8 mm to in mm in. A Tilt (B) 1.2 mm in. Setting load / Setting length 64.7 N / 27.0 mm 6.6 kgf / 27.0 mm 14.6 lbs / in N / 27.0 mm 5.6 kgf / 27.0 mm 12.3 lbs / in.

3 (3/14) Rocker arm shaft to rocker arm to mm to in. Rocker arm shaft O.D to mm to in. Rocker arm I.D to mm to in. Push rod Alignment 0.25 mm in. Tappet to tappet guide to mm to in mm in. Tappet O.D to mm to in. Tappet guide I.D to mm to in. Timing gear Backlash (Crank gear to idle gear) to mm to in. Backlash (Idle gear to cam gear) to mm to in. Backlash (Idle gear to injection pump gear) to mm to in. Backlash (Crank gear to oil pump drive gear) to 0.123mm to in. Idle gear Side clearance 0.20 to 0.51 mm to in. 0.8 mm in.

4 (4/14) Idle gear shaft to idle gear bushing to mm to in. 0.1 mm in. Idle gear shaft O.D to mm to in. Idle gear bushing I.D to mm to in. Camshaft Alignment 0.01 mm in. Camshaft Side clearance 0.15 to 0.13 mm to in. 0.5 mm in. Cam Height (Intake) mm in mm in. Height (Exhaust) mm in mm in. Camshaft journal to cylinder block bore to mm to in. Camshaft journal O.D to mm to in. Cylinder block bore I.D to mm to in.

5 (5/14) Piston pin bore Piston pin bore I.D to mm to in mm in. Piston pin to small end bushing to mm to in mm in. Piston pin O.D to mm to in. Small end bushing I.D to mm to in. Piston pin to small end bushing (Spare parts) to mm to in. Small end bushing I.D to mm to in. Piston ring Ring gap (Top ring) D772-E2B 0.15 to 0.30 mm to in to 0.40 mm to in mm in mm in to 0.35 mm to in mm in. Ring gap (Second ring) 0.30 to 0.45 mm to in to 0.40 mm to in mm in mm in. Ring gap (Oil ring) 0.35 to 0.50 mm to in to 0.30 mm to in to 0.30 mm to in mm in mm in mm in to 0.35 mm to in mm in.

6 (6/14) Piston ring groove to piston ring Connecting rod Clearance (Second ring) Clearance (Oil ring) to mm to in to mm to in to mm to in to 0.08 mm to in. Alignment 0.05 mm in. Crankshaft Alignment 0.02 mm in. Crankshaft journal to crankshaft bearing to mm to in. 0.2 mm in. Crankshaft journal O.D to mm to in. Crankshaft bearing 1 I.D to mm to in to mm to in to mm to in.

7 (7/14) Crankshaft journal to crankshaft bearing 3 (Intermediate) to mm to in. 0.2 mm in. Crankshaft journal O.D to mm to in to mm to in. Crankshaft bearing 3 I.D to mm to in to mm to in. Crankshaft journal to crankshaft bearing 2 (Flywheel side) to mm to in. 0.2 mm in. Crankshaft journal O.D to mm to in. Crankshaft bearing 2 I.D to mm to in. Crankpin to crankpin bearing to mm to in. Crankpin O.D to mm to in. Crankpin bearing I.D to mm to in.

8 (8/14) Crankshaft Side clearance 0.15 to 0.31 mm to in. 0.5 mm in. Cylinder Bore I.D. (Standard size) to mm to in to mm to in to mm to in mm in mm in mm in. Bore I.D. (Oversize) to mm to in to mm to in mm in mm in to mm to in mm in.

9 (2) LUBRICATING SYSTEM Engine oil pressure Engine oil pressure (At idle speed) 49 kpa 0.5 kgf/cm 2 7 psi (9/14) Engine oil pressure (At rated speed) 196 to 441 kpa 2.0 to 4.5 kgf/cm 2 28 to 64 psi 147 kpa 1.5 kgf/cm 2 21 psi Inner rotor to outer rotor (Oil pump) Clearance 0.03 to 0.14 mm to in. Outer rotor to pump body (Oil pump) Clearance 0.07 to to Inner rotor to cover (Oil pump) Clearance 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 lbs) 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 water leak at 157 kpa 1.6 kgf/cm 2 23 psi Radiator cap Pressure falling time 10 seconds or more for pressure falling from 88 to 59 kpa (from 0.9 to 0.6 kgf/cm 2, from 13 to 9 psi)

11 (4) FUEL SYSTEM Injection pump (3600 min -1 (rpm)) 0.33 to 0.37 rad. (19 to 21 ) before T.D.C. (11/14) Injection timing (3200 min -1 (rpm)) (3200 min -1 (rpm)) 0.28 to 0.31 rad. (16 to 18 ) before T.D.C to 0.33 rad. (17 to 19 ) before T.D.C. (3600 min -1 (rpm)) 0.33 to 0.37 rad. (19 to 21 ) before T.D.C. Pump element Fuel Tightness MPa 140 kgf/cm psi Delivery valve Fuel Tightness 10 seconds to MPa 140 to 130 kgf/cm to 1849 psi 5 seconds to MPa 140 to 130 kgf/cm to 1849 psi Injection nozzle Injection pressure to MPa 140 to 150 kgf/cm to 2133 psi Injection nozzle Valve seat tightness No fuel leak at MPa 130 kgf/cm psi

12 (5) ELECTRICAL SYSTEM Starter Commutator O.D. Electromagnetic drive type Planetary gear reduction type 28.0 mm in mm in mm in mm in. (12/14) Difference of commutator O.D's Electromagnetic drive type Planetary gear reduction type Less than 0.05 mm in. Less than 0.02 mm in. 0.4 mm in mm in. Starter Mica under cut 0.50 to 0.80 mm to in mm in. Starter Electromagnetic drive type 16.0 mm in mm in. Brush length Planetary gear reduction type 14.0 mm in. 9.0 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 Dynamo No-load output AC 20V or more at 5200 min -1 (rpm) Dynamo Regurating voltage 14 to 15 V at 5200 min -1 (rpm) Alternator Stator resistance Less than 1.0

14 (14/14) Alternator Rotor resistance 2.9 Alternator Slip ring O.D mm in mm in. Alternator Brush length 10.0 mm in. 8.5 mm in. Glow plug Resistance Approx. 0.9

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 screw Injection pipe retaining nut Overflow pipe retaining nut (1/3) 6.86 to 11.3 N m 0.7 to 1.15 kgf m 5.1 to 8.3 ft-lbs 24.5 to 34.3 N m 2.5 to 3.5 kgf m 18.1 to 25.3 ft-lbs 19.6 to 24.5 N m 2.0 to 2.5 kgf m 14.5 to 18.1 ft-lbs Nozzle holder assembly Glow plug Rocker arm bracket screw 49.0 to 68.6 N m 5.0 to 7.0 kgf m 36.2 to 50.6 ft-lbs 7.85 to 14.7 N m 0.8 to 1.5 kgf m 5.8 to 10.8 ft-lbs 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.2 to 8.3 ft-lbs Cylinder head screw Cylinder head tightening order (A) 2 cylinder model (B) 3 cylinder model j f b c g n j b g f c k i a h e d m e d i a h l 37.3 to 42.2 N m 3.8 to 4.3 kgf m 27.5 to 31.1 ft-lbs (A) 2 cylinder model a j (B) 3 cylinder model a n

16 (2/3) Fan drive pulley screw Gear case screw Idle gear shaft mounting screw 98.1 to N m 10.0 to 11.0 kgf m 72.3 to 79.6 ft-lbs 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.2 to 8.3 ft-lbs 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.2 to 8.3 ft-lbs Camshaft set screw Fuel camshaft set screw & Governor forklever set screw Connecting rod screw 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.2 to 8.3 ft-lbs 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.2 to 8.3 ft-lbs 26.5 to 30.4 N m 2.7 to 3.1 kgf m 19.5 to 22.4 ft-lbs Flywheel screw Bearing case cover mounting screw Main bearing case screw to 58.8 N m 5.5 to 6.0 kgf m 39.8 to 43.4 ft-lbs 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.2 to 8.3 ft-lbs 12.7 to 15.7 N m 1.3 to 1.6 kgf m 9.4 to 11.6 ft-lbs

17 (3/3) Main bearing case screw 2 Nozzle holder Oil pressure switch 26.5 to 30.4 N m 2.7 to 3.1 kgf m 19.5 to 22.4 ft-lbs 34.3 to 39.2 N m 3.5 to 4.0 kgf m 25.3 to 28.9 ft-lbs 14.7 to 19.6 N m 1.5 to 2.0 kgf m 10.8 to 14.5 ft-lbs Starter (C terminal nut) Alternator pulley nut 5.9 to 11.8 N m 0.6 to 1.2 kgf m 4.3 to 8.7 ft-lbs 58.3 to 78.9 N m 5.95 to 8.05 kgf m 43.0 to 58.2 ft-lbs (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 6.9 ft-lbs 17.7 to 20.6 N m 1.8 to 2.1 kgf m 13.0 to 15.2 ft-lbs 39.2 to 45.1 N m 4.0 to 4.6 kgf m 28.9 to 33.3 ft-lbs 62.8 to 72.6 N m 6.4 to 7.4 kgf m 46.3 to 53.5 ft-lbs Special Grade 9.8 to 11.3 N m 1.00 to 1.15 kgf m 7.23 to 8.32 ft-lbs 23.5 to 27.5 N m 2.4 to 2.8 kgf m 17.4 to 20.3 ft-lbs 48.1 to 55.9 N m 4.9 to 5.7 kgf m 35.4 to 41.2 ft-lbs 77.5 to 90.2 N m 7.9 to 9.2 kgf m 57.1 to 66.5 ft-lbs

SERVICING SPECIFICATIONS (1) ENGINE BODY

SERVICING SPECIFICATIONS (1) ENGINE BODY (1/14) Lubricating oil capacity Oil pan depth 124 mm (4.88 in.) 7.0 L 1.85 U.S.gals. 1.54 lmp.gals. 9.5 L 2.51 U.S.gals. 2.09 lmp.gals. Oil pan depth 90 mm (3.54