Cylinder and Manifold Pressures
| Compression pressure: | | |
|---|
| Standard | kPa | 1800 |
| Maximum difference between any two cylinders | kPa | 150 |
| Vacuum check at idle speed within five seconds of starting | kPa | Greater than -50 |
Turbocharger
| Turbocharger boost pressure control valve rod stroke: | | |
|---|
| With diesel particulate filter (DPF) at -50 kPa | mm | 3.85 to 4.85 |
| Without DPF at 138 kPa | mm | 1.5 to 2.5 |
Cylinder Head to Camshaft Housing Alignment
| Misalignment between camshaft housing and cylinder head, dimension ”a” | mm | -0.1 to 0.1 |
Camshaft and Camshaft Housing
| Camshaft bearing journal diameter: | | |
|---|
| Journal 1 | mm | 38.50 to 38.515 |
| Journal 2 | mm | 38.00 to 38.015 |
| Journal 3 | mm | 30.00 to 30.015 |
| Camshaft housing bearing bore diameter: | | |
| Journal bore 1 | mm | 38.545 to 35.570 |
| Journal bore 2 | mm | 38.045 to 38.070 |
| Journal bore 3 | mm | 30.045 to 30.070 |
Cylinder Head Gasket
| Gasket Identification | Gasket thickness (mm) | Piston protrusion (mm) |
|---|
| Without hole (type A) | 0.67 to 0.77 | 0.028 to 0.127 |
| One hole (type B) | 0.77 to 0.87 | 0.128 to 0.227 |
| Two holes (type C) | 0.87 to 0.97 | 0.228 to 0.317 |
Cylinder Head
| Cylinder head height, standard | mm | 105.45 to 105.55 |
|---|
| Gasket face distortion, maximum | mm | 0.10 |
| Cylinder head height (mm): | Selected cylinder head gasket (according to piston protrusion measurement) | Installed cylinder head gasket |
|---|
| Type A | Type B |
| 105.35 to 105.45 | Type B | Type C |
| Type C | Replace cylinder head |
| Type A | Type C |
| 105.25 to 105.35 | Type B | Replace cylinder head |
| Type C | Replace cylinder head |
| 105.25 or less | Replace cylinder head |
Valves, Valve Guides and Valve Springs
| Valve: | | |
|---|
| Stem diameter, inlet and exhaust | mm | 5.974 to 5.992 |
| Stem to valve guide clearance, inlet and exhaust | mm | 0.028 to 0.064 |
| Valve seat width at 45° | mm | 1.35 to 1.62 |
| Valve guide bore, inlet and exhaust | mm | 6.020 to 6.038 |
| Valve spring: | | |
| Free length | mm | 37.9 |
| Length under load: | | |
| 162 to 180 N | mm | 31.0 |
| 361 to 395 N | mm | 23.5 |
Cylinders, Pistons and Piston Rings
| Cylinder bore diameter: | | |
|---|
| Category A | mm | 69.600 to 69.610 |
| Category B | mm | 69.610 to 69.620 |
| Category C | mm | 69.620 to 69.630 |
| Cylinder bore diameter to be rebored | mm | 70.000 to 70.010 |
| Cylinder bore taper, maximum | mm | 0.001 |
| Cylinder bore ovality, maximum | mm | 0.005 |
| Piston diameter: | | |
| Marked A on piston | mm | 69.546 to 69.556 |
| Marked B on piston | mm | 69.556 to 69.566 |
| Marked C on piston | mm | 69.566 to 69.576 |
| Oversize piston diameter | mm | 69.946 to 69.956 |
| Piston to cylinder bore clearance | mm | 0.024 to 0.064 |
| Piston ring groove clearance: | | |
| Top ring | mm | 0.11 to 0.15 |
| Second ring | mm | 0.05 to 0.09 |
| Oil ring | mm | 0.03 to 0.07 |
| Piston ring gap: | | |
| Top ring | mm | 0.20 to 0.30 |
| Second ring | mm | 1.00 to 1.50 |
| Oil ring | mm | 0.25 to 0.50 |
| Piston pin: | | |
| Clearance in connecting rod piston pin end | mm | 0.019 to 0.03 |
| Clearance in piston | mm | 0.008 to 0.018 |
| Piston pin diameter | mm | 22.982 to 22.987 |
| Piston bore diameter | mm | 22.995 to 23.000 |
| Connecting rod: | | |
| Piston pin bore | mm | 23.006 to 23.012 |
| Connecting rod journal diameter | mm | 45.734 to 45.744 |
| Side clearance to crankshaft | mm | 0.12 to 0.45 |
| Connecting rod bearing clearance to crank pin | mm | 0.030 to 0.062 |
| Crank pin bearing thickness: | | |
| Painted red | mm | 1.546 to 1.552 |
| Painted blue | mm | 1.550 to 1.556 |
| Undersize crank pin bearing: | | |
| Painted brown, crankshaft pin diameter | mm | 42.464 to 42.473 |
| Painted green, crankshaft pin diameter | mm | 42.455 to 42.464 |
| Undersize crank pin bearing thickness: | | |
| Painted brown | mm | 1.609 to 1.615 |
| Painted green | mm | 1.613 to 1.619 |
Crankshaft and Cylinder Block
| Crank pin diameter: | | |
|---|
| Class A | mm | 42.591 to 42.600 |
| Class B | mm | 42.582 to 42.591 |
| Crankshaft thrust bearing thickness: | | |
| Standard | mm | 2.290 to 2.320 |
| Oversize | mm | 2.420 to 2.450 |
| Crankshaft thrust play | mm | 0.19 to 0.30 |
| Main bearing bore diameter: | | |
| Stamped 1 | mm | 54.710 to 54.714 |
| Stamped 2 | mm | 54.714 to 54.718 |
| Stamped 3 | mm | 54.718 to 54.722 |
| Main bearing journal diameter: | | |
| Stamped A | mm | 50.994 to 51.000 |
| Stamped B | mm | 50.988 to 50.994 |
| Stamped C | mm | 50.982 to 50.998 |
| Standard size main bearing thickness: | | |
| Without thrust bearing, with standard size thrust bearing: | | |
| Painted red | mm | 1.836 to 1.841 |
| Painted blue | mm | 1.841 to 1.846 |
| Painted yellow | mm | 1.846 to 1.851 |
| With oversize thrust bearing: | | |
| Painted red / white | mm | 1.836 to 1.841 |
| Painted blue / white | mm | 1.841 to 1.846 |
| Painted yellow / white | mm | 1.846 to 1.851 |
| Undersize main bearing thickness: | | |
| Painted brown | mm | 1.899 to 1.904 |
| Painted green | mm | 1.904 to 1.909 |
| Painted black | mm | 1.909 to 1.914 |
| Painted brown / white | mm | 1.899 to 1.904 |
| Painted green / white | mm | 1.904 to 1.909 |
| Painted black / white | mm | 1.909 to 1.914 |
Engine Lubrication
| Oil pressure specification: | | |
|---|
| At specified idle speed | kPa | 100 |
| At 4000 rpm | kPa | 300 to 400 |
| Oil pump: | | |
| Radial clearance between outer rotor and timing chain cover | mm | 0.10 to 0.23 |
| Side clearance for inner rotor | mm | 0.050 to 0.075 |
Oil Pan
| Oil capacity (replacement with oil filter) | litre | 3.1 |
Oil Specification
| Grade | Viscosity-SAE |
|---|
| GM-LL-B-025 | 0w-30, 0w-40 , 5w-30 , 5w-40 |
