CONTENTS ENGINE MECHANICAL orm EM PREPARATION. sees 5 EM. 2 ENGINE COMPONENTS —Outer Parts... EM. 6 CHECKING COMPRESSION PRESSURE (On-Vehicle Service! EM. 8 CYLINDER HEAD . EM. 9 CYLINDER HEAD —Removal(On-Vehicle Service) . EW-10 CYLINDER HEAD —Disassembly sees EMA CYLINDER HEAD —Inspection .... cove EMAB. CYLINDER HEAD —Assembly ...... M49 CYLINDER HEAD —Installation (On-Vehicle Service) M20 OIL SEAL REPLACEMENT (On-Vehicle Service) - EM.23 TURBOCHARGER ; EM.25 ENGINE OVERHAUL . a EM-27 ENGINE OVERHAUL —Disassembly - EM-28 ENGINE OVERHAUL —Inspection and Replacement . . - M31 ENGINE OVERHAUL ~Assembly .....++ we > EMA SERVICE DATA AND SPECIFICATIONS (6.0.8) £M-48PREPARATION SPECIAL SERVICE TOOLS *: Special too! or commercial equivalent Engine application Tool unter Teel nave Deesinion roos | Tuas [Oe sToso1s00" Dissenting nd Ena ond asembly somolg erosor oon Engi and @sroso1200 x |x | x ae revr08800" Ene stocment a (Me |e sevircnzo" s Emi sachet eS x |x | x @ Kv10109210" @ Disassembling and Vater ssombig ve comprar cones @ KVv10111200" Adapter | x x x revor07000" Discanbing ake Ve is puller - oie ele le revt0oH0n Insating veo Valois it sa elx lx $T11033000° Removing valve guide Vale wie it clei EM-2 Too! nt Tool na kv Valve 9 sTti102 Valve 9 8.0mm @kvt val @xvi Ad a @xvi Ada, @xv Ada on227 and a7 PREPARATION Tool number. Tool name Kv11103900° Valve guide ditt Description Engine application T023 1025 [T27 and oz Installing valve guide ‘sT11032000" Valve guide reamer 8.0 mm (0.315 in) dis. Reaming valve guide Oxvirion10 Valve sat remover ® kv11103510 ‘Adapter (Intake) @® kv11103520 ‘Adapter (Exhaust) ® Kvin104810 ‘Adapter (loake) ® kvi1104920 Adapter (Exhaust) @ kvit1o3610 Adapter (Intake @ Kv11103620 ‘Adapter (Exhaust) Removing valve seat ®@@OO0O i @ st18243000 Valve seat drift @Kvirios710 ‘Adaptor (Intake) @ vi1103720 Adapter (Exhaust) @ kvi1i03810 ‘Adapter (Intake) @® kv11103820 ‘Adapter (Exhaust) oo Installing valve seat EM-3PREPARATION Engine application Tool r Tool number viption Ta and Tool name Denrins tora | Tozs [T222ard | Toot @ kvitio4o10 Removing and x x x kvit Cylinder liner tool instling cylinder Camb @xviri01020 liner x = = replac Adapter for @xv removing 90 ey @ Kvi1104700 7 z = ee Adapter for u removing x @xv @ kvi1i04110 ye - = x - ‘Adapter for b removing @Q os @ Kvi1104030 x x x ri Adapter for installing .Em403470000* Instaling piston into Piston ring cylinder x x compressor = Kyat 103380 Preventing rank kvi0 Engine stopper shaft from rotating Inject @kviti03310 sear Stopper plate @ Kvi0105630 x x x Stopper gear Kvn Inject ear sriee1000"* Removing ot Oe Pilot bushing puller bushing x x x @eo £ Cor L ada plu @eo Cot ada hot ws30t Tubs} EM-4PREPARATION Too! number Too! name Description Engine application 1023 1025 TO27 and To27T Kv11 104580 ‘Cam bushing replacer set @Kv11104510 Replacer bar @ kv11104520 Guide plate @kv11104530 ‘Adopter (1st bushing) @s115243000 Drift Removing cam bushing or installing cam bushing «y10109300" Injection pump drive gear holder Preventing drive gear from rotating (vE-typeb kv11103000" Injection pump drive ‘ear puller Removing drive gear (VE-typel Devre601000 Compression goure @ ED19600600 Compression gauge adapter (for glow lug hoe) @ 019600700 Compresion gouge adapter (for injector hole) ¢ Checking com ws3e930000" “Tube presser ) Pressing the tube of liquid gasket EM-5Except TD27T & 4103-04,22-28) ®. bee ane Mise a2 ¢ @a-aa2-on- (16-21, 12.18) ENGINE COMPONENTS —Outer Parts ou Aus eee . (19-25, 14-10) ae aN soe ia%e0s0 Drosping reese aie 3 ois Pe bie * | os om Fra. & aK *"Z 2 a0 85, a en) er / (7a / Kirconditicner Om: / compressor Se Pio. (83°42, 22-201 16-21 (18-24, 12-15) ]we Jao-a 1-42, 22-30) * a é Z Ss x o 7 ENGINE COMPONENTS —Outer Parts (Except TD27T_ 64 ~ E.R, contrat valve = yi ae Gs od of 19(1.3-1.9,9- 141, Engine sie e-21 98-21, 12-15) = 22 it 22, 12-16 oe Mey Clean Dh 7-23 09.23,12-97 {F]13- 1911.3 -19,9-14) 7 ‘Plzs- ‘80)/ 7) | a sone 21 (18-21,12-15) za-31 6, ~ 30° 86,22- 751 Mag % ce es Bp aain9-22,12-19 Ae & i.0-3s, 22-25 17.23 (17-23,12.17) men (1.0-1.3,7-9) o isa" F5%a0.40 S i, iS no _ fee WS Pista ' (3.94.0, 22-29) o a [P)s0-41 13.1-42,22-30) (a4, 22-30) ©): wm kgm, feb) semsorc —EM-7CHECKING COMPRESSION PRESSURE (On-Vehicle Service) 1. Warm up engine, 2. Remove glow plate and glow plugs. 3. Fit compression gauge adapter to cylinder head, | : Compression gauge adapter 15-20Nm (1.5 - 2.0 kgm, 11-14 ft-lb) 4, Set no fuel injected condition. © VEtype Disconnect fuel cut solenoid wire. * In-ine type Set control lever of injection pump at zero injection. 5. Crank engine, then read gauge indication. | ‘¢ In case of engine equipped with In-line type, depress ac- celerator pedal fully and crank engine. } ‘¢ Engine compression measurement should be made as quickly as possible. Compression pressure: Unit: KPa (bar, ka/om?, psiN/200 rpm 2,942 (29.4, 30, 427) Minimum 2,482 (24.5, 25, 366) Differential limit between cylinders 294 (2.9, 3,43) 6. If cylinder compression in one or more cylinders is low, pour a small quantity of engine oil into cylinders through the glow holes and retest compression. —— ‘If adding oil helps the compression pressure, chances are that piston rings are worn or damaged. ‘+ If pressure stays. low, valve may be sti properly. '* If cylinder compression in any two adjacent cylinders is low, and if adding oil does not help the compression, there is leakage past the gasketed surface. Oil and water in combustion chambers can result from this problem. ing or seating im- EM-8ress ace quickly | 200 rpm 2” 38) w, pour he glow are that ing im- sislow, there is om this | CYLINDER HEAD 1-2 (01-02,07-14) a — Roker cover pate {Be 20 (9.8-2.0, 11-14) Ase bolt Rocker cover Rocker cover gasket 6 tow plug (18-20 195-20, 11-14) vt PRE —cytinsr ne sos 9 Valve cotter soning one —____@ Valve oi se 3] —— Valve xing — Nozzle gasket (3 ovine nos Tica tae ei — eS Valve seat — ‘ 1D): Nim (kom, rao} sensz06|CYLINDER HEAD — Removal (On-Vehicle Service) ‘Engine Removal je. cerstinuairection | 4. Set No, 1 cylinder at T..C. on its compression stroke. é 2. Drain engine coolant from drain plugs on cylinder block and radiator. il 3. Remove air cleaner and/or air duct. 4, Remove alternator adjusting bolt. 5. Disconnect exhaust manifold from front exhaust tube. \Crankshate 6. Disconnect radiator outlet hose and thermostat housing ‘alley water inlet hose. Cranksatt pulley 7. Remove fuel injection tube assembly and spill tube, | 8, Remove injection nozzle holder and top nozzle gasket using _ deep socket wrench, 9. Remove rocker cover. 10, Remove rocker shaft with rocker arms. 11, Remove push rods, ji EM-10 iCYLINDER HEAD — Removal (On-Vehicle Service) Removal (Cont'd): 12, Remove cylinder head bolts in numerical order and remove cylinder head, Head warpage or cracking could result from removing in in- correct order. EM-11CYLINDER HEAD assembly t Disassembly Kyrotes210 Kv1o11 1200 ‘5e66270| 4, a b. Remove following parts: Intake manifold Exhaust manifold Thermostat housing Aiternator adjusting bar & engine stinger Glow plate and glow plugs Remove valve component parts with Tool. Remove valve oil seals with Tool. Disassemble rocker shaft assembly, Remove rocker shaft lock bolt. Remove valve rocker and rocker shaft bracket. If it is difficult to remove rocker shaft bracket, immerse rocker shaft assembly in oil of 70°C (158° F) for afew minutes and then remove bracket, EM-12 } | | } |CYLINDER HEAD —Inspection ait: me ind ‘Sewseca CYLINDER HEAD DISTORTION Cylinder head distortion: Standard Less than 0,07 mm (0.0028 in) Limit 0.2. mm (0.008 in) If beyond the specified limit, correct with @ surface grinder. Cylinder head height should be greater than 89.7 mm (3.631 in} after surface has been ground. VALVE GUIDE CLEARANCE © Valve guide clearance should be measured parallel with rocker arm. (Generally, a large amount of wear occurs in this direction.) Stem to quide clearance Limit Intake 0.15 mm (0.0059 in) Exhaust 0.20 mm (0.0079 in) Maximum allowable deflection (Dial indicator reading) Intake 0.30 mm (0.0118 in} Exhaust 0.40-mm (0.0157 in) To determine the correct replacement part, measure valve stem diameter and valve quide inner diameter. Valve stem diameter: ‘Standard Intake 7,962 - 7.977 mm (0.3135 - Exhaust 7.945 - 7.960 mm (0.3128 - 0.3134 in) Valve guide inner 8,00 - 8.015 mm (0.3150 - 0.3156 in) 3141 in) VALVE GUIDE REPLACEMENT 1. Drive out valve guide with a press (under a 20 KN (2t, 2.2 US ton, 2:0 Imp ton) pressure] or hammer, and suitable tool. EM-13.CYLINDER HEAD —Inspection 0500 /* eration {mm 051) ‘Gone width 2:4 rm (0.083 in} ox. 0.0. semoza] st "15243000 f 2. Press service valve guide onto cylinder head using suitable ‘tool until the guide projects out 13 mm (0.51 in). ! 3, Ream valve guide. Finished size: 8,000 - 8.015 mm (0.3150 - 0.3186 in) VALVE SEATS Check valve for any evidence of pitting at valve contact surface, and reseat or replace if worn out excessively. ‘© When repairing valve seats, check valve and valve guide for wear beforehand, If worn, replace them, Then correct valve. seat. © The cutting should be done with both hands for uniform: cutting. REPLACING VALVE SEAT FOR SERVICE PARTS 1. Bore out old seat, until it collapses or remove valve seats with Tool. Place a copper seat between contact surface of Tool and cylinder head. PL RAN PT am | \ Ce7| cy La | 2, Place new valve seats on dry ice and allow them to cool for_ five minutes. WARNING: Do not touch cooled valve seats with bare hand. 3. Heat cylinder head to 80°C (176"F). 4, Install cooled valve seats on cylinder head with Tool, EM-14sive seats ‘cylinder cool for CYLINDER HEAD —Inspection semsaoa mark semssoc 5. Stake exhaust valve seat at five places with punch. When staking valve seat, select different places than those staked, before. 6. Cut or grind valve seat using suitable too! at the specified dimensions as shown in S.0.S. 7, After cutting, lap valve seat with a lapping compound, 8. Check contact condition of valve seat. COMBUSTION CHAMBER Check combustion chamber for cracks and other damage. If necessary, replace. REPLACING COMBUSTION CHAMBER Usually combustion chamber should not be removed. 1. Remove combustion chamber so that cylinder head cannot be damaged. 2. Install combustion chamber, Identification mark Outer a {on combustion chamber) | “0” 34 (1.34) 1023 2 7026 = 37 (1.46) 027 3 To27T (1) Coo! combustion chamber with dry ice for approximately 5 to 10 minutes. WARNING: Do not touch cooled combustion chamber with bare hand. EM-15CYLINDER HEAD —Inspection semeasa| (2) Align combustion chamber knock pin with cylinder head notch, and drive in combustion chamber with a soft hammer. 3, Check amount of protrusion of combustion chamber. Protrusion: Standard =0.06 to 0.10 mm (0.0020 to 0.0039 in) VALVE DIMENSIONS Check dimensions in each valve, For dimensions, refer to 8. S. When valve head.has been worn down to 0.5 mm (0.020 in) in margin thickness, replace the valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less. VALVE SPRING SQUARENESS Outof-square “S”: Less than 2,0 mm (0.079 in) VALVE SPRING PRESSURE LOAD Refer to 8.0.5. EM-16 Iader head hammer. 139 in) oS.DS. 020 in) in 308 in) or CYLINDER HEAD —Inspection semsaea VALVE LIFTER AND PUSH ROD Valve lifter 1. Check valve lifters for excessive wear on the face. ith new ones if worn beyond repair, sep Valve lifter to lifter hole clearance: ‘Standard 0.030 - 0.073 mm (0.0012 - 0.0029 in) Limit Less than 0,20 mm (0.0079 in) Valve lifter outer diameter “A: ‘Standard £24,960 - 24.970 mm (0.9827 - 0.9831 in) Cylinder block valve lifter hole diameter “B’’: Standard 25.000 - 25.033 mm (0.9843 - 0.9855 in) Push rod 1. Inspect push rod for excessive wear on the face. 2. Replace if worn or damaged beyond repair. 3. Check push rod for bend using a dial gauge. Maximum allowable bend (Total indicator reading) ‘Less than 0.5 mm (0.020 in) ROCKER SHAFT AND: ROCKER ARM 1. Check valve rockers, brackets and rocker shafts for scoring, wear or distortion. Replace if necessary. EM-17| CYLINDER HEAD —Inspection | 2. Check clearance between valve rockers and rocker shaft, { specified clearance is exceeded, replace affected valve rocker or shafts i Specified clearance: f Limit ‘Less than 0.15 mm (0.0059 in) Rocker shaft outer diameter Standard k 19.979 - 20.000 mm (0.7866 - 0.7874 in) | senor Rocker arm inner diameter “B”: Standard 20.014 - 20.035 mm (0.7880 - 0.7888 in) 5. Check rocker shaft bend at its center. If bend is within Specified limit, straigrten it; and if it is greater than specified limit, replace rocker shaft, f Rocker shaft bend (Total indatr rating): Limit Less than 0.3 mm (0,012 in) { MEASURING CYLINDER HEAD TO VALVE DISTANCE Measure distance from cylinder head surface to intake and exhaust valves. If specified distance is exeaeded, replace vat or vaive seats) Specified distance: ‘Standard Intake 0.275 -0.675 mmm (0.0108 - 0.0266 in) Exhaust } 0.305 - 0,695 mm, (0.0120 - 0.0274 in) | Limit Less than 1.25 mm (0.0492 in) for intake and exhaust valves f EM-18CYLINDER HEAD —Assembly semea7s) Intake valve mark GE GE semozsa| le pitch ow piten Cinder nese sive SE MS389) 1, Assemble rocker shaft component parts. ‘¢ Identification of rocker arms Identification mark Engine For use with {on rocker arm) ° A 23 | Intake and exhaust 025, To27 | ake and T0277 | exhaust 2. Install valve component parts ¢ Identification of valves es ldentifieation mark {on intake and exhaust valve} Engine Intake valve Exhaust valve 1 A 7023 2 B 1025 c 1027 8 : D wut © Always use new valve oil seal. (Refer to OIL SEAL RE- PLACEMENT.) ‘@ Install valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side, —M-19CYLINDER HEAD — Installation (On-Vehicle Service) 1, Install cylinder head gasket, ¢__ Identification of cylinder head gaskets Identification eu hole Inner diameter es {on cylinder head gasket) ‘dram Cin) nine - 905 (3.563) 1023 2 94.4 (3.717) 1025 1 1027 + 97.5 (3.839) = To27T ‘a, When replacing only cylinder head gasket, install same grade ‘gasket as the one formerty used. 'b, When replacing or repairing cylinder block, cylinder head, piston, connecting rod and crankshaft, select gasket at follows: (1) Measure piston projection. ‘© Set each piston at its Top Dead Center. With piston held in that position, measure its projections at two points, ‘© Calculate the average value of the two measurements. © Determine the amount of projection of the other three pistons, (2) Select suitable cylinder head gasket which conforms to the largest amount of projection of the four pistons. seusun Unt mr wrap var pson preieions [ uke thitoen | SOR Testtonorevaoossy | va0veosmy fa ani8-068 o00%8-c0o8H | 1ast00s |? ~ noe win 068 0056 | raovoo%e | 2 Make sure that No. 1 piston is at T.D.C. on its compression stroke.CYLINDER HEAD — Installation (On-Vehicle Service) Install cylinder head. Wentfcation number rgine (on eylinder hoa (on cylinder head) Engine om Float mark Punch mark 025 1 - Toes zr Ext port 2 4 Tae a 2 = To27 a = 1277 ame grade der head, gasket a 3, Apply oil to the thread portion and seat surface of bolts and aheld in tighten cylinder head bolts using Too! CAUTION: 8 © Tightening procedure yer three 1st: Tighten bolts t0:39- 44 Nm (4.0 -4.5 kgm, 29 -33 feb) ns to the 2nd: Tighten bolts to 54 -59 N-m {55 -6.0 kg-m, 40 - 43 ftb) 3rd: (1) Mark exhaust side of cylinder head and cylinder head bolts with paint as shown. (2) Turn all bolts 90+ 10 degrees clockwise, (3) Check that the paint mark of each bolt is facing ‘the front of the vehicle, 4, Apply engine oil and install push rods. 5, Install rocker shaft assembly. Adjusting intake and exhaust valve clearance tentatively. Refer to section MA, ss sehieezy EM-21CYLINDER HEAD — Installation (On-Vehicle Service) sesiezse| 6. . © Install rocker cover with rocker cover plate. Be sure the “F’” mark on rocker cover plate faces upward ar is at the front end, When replacing rocker cover gasket, bend slit of rocker cov baffle plate a little to hold the gasket. Do not twist gasket. 7. Install glow plugs and glow plate. Install new top nozzle gasket and injection nozzle. |. Install spill tube and injection tube. Connect thermostat housing water inlet hose and radiator hose. | = After assembling all disassembled parts, fill radiator and) engine with new coolant up to filler opening. rai in onIpward a >eker cor gasket. OIL SEAL REPLACEMENT (On-Vehicle Service) > __ OIL SEAL INSTALLING DIRECTION © When installing a new front or rear seal, make sure its mount- ing direction is correct. nin Engine toe aa Ci seat lp unt sa ip CRANKSHAFT FRONT OIL SEAL 1, Remove radiator shroud. 2, Remove cooling fan, 3, Remove drive belts. 4, Remove crank pulley. §. Remove crankshaft oil seal. ‘© Be careful not to damage sealing surfaces of crankshaft. 6. Coat new oil seal with engine oil and install it in place. CRANKSHAFT REAR OIL SEAL 1. Dismount transmission. 2. Remove clutch cover assembly. 3. Remove flywheel and rear plate. 4, Remove engine gusset and oil pan. 5, Remove oil seal retainer assembly, then remove oil seal © Be careful not to damage sealing surfaces of crankshaft. 6. Coat new oil seal with engine oil and install it in place. VALVE STEM OIL SEAL 1, Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring 4, Remove valve oil seals. EM-23OIL SEAL REPLACEMENT (On-Vehicle Service} Kv1T19H007- | _§. Apply engine cl to valve oil sel and instal tin place. Pad — XN [Air teak Units nm in jinn suction [ Exhaust exh Broken Sludge Broken Disconns By-pass Controle EM-24TURBOCHARGER i Removal and Installation Turbocharger should not be disassembled. 1. Drain engine coolant. 2. Remove the following: * Air duct and hoses # Air intake pipe Heat shield plates Exhaust front tube © Oil tube © Water tubes 3. Remove turbocharger from exhaust manifold a Inspection Condition 1: Low engine power Probable case Cortectve action Tilak at the connection of compressor housing and | suction hose/inlet tube, or inlet tube and intake manifold. Correct the connection. Exhautolak athe conneetion of turbine houing | sedexnaust manifold, connecting tube or exhaust outer [>| _Covreet the connection or replace gasket. By pes valves stuck open. | ‘Stick oF worn journal or bearing || Broken shaft || Replace turbocharoersisembly, Sudge on back of tubine whee! |, ‘Broken turbine wheal =| Condition 2: Excessively high engine power CL Probable cause Corrective action Disconnected or oracked rubber hose of by-pass valve Rerciee -—+ Correct oF replace rubber hose By-pass valve is stuck closed. || Replace turbocharger assembly. Controller diaphragm is broken. |_| EM-25TURBOCHARGER Inspection (Cont'd) Condition 3:_ Excessively high oil consumption or exhaust shows pale blue smoke Probable cause Corrective action it eak atthe connection of lubricating ol pasage _ -—»| Corect the connection, (i ea ato sea of turbine |_| Oil leak at oi eal of compressor || Replace turbocharger assembly Worn journal or bearing |_| 1. Inspect turbine and compressor wheel as follows: jally check for cracks, clogging, deformity or other damage, ‘© Revolve wheels to make sure that they turn freely withou any abnormal noise or friction. ‘© Measure play in axial direction. Play (axial direction): 0.002 - 0.006 mm (0.0001 - 0,0002 in) ser72e) a 2. Check operation of by-pass valve controler. Sy-pes wave conver, © Move by-pass valve to make sure that it is not sticking o a scratched. © Measure rod end play of the by-pass valve controller, Do not apply more than 93.3 kPa (933 mbar, 770 mmHg, 27.5 inkig) pressure to controller diaphragm. By-pass valve controller stroke/pressure: 1.6 mm (0,059 in)/84,0 -89.3 kPa (840 - 893 mbar, 630 - 670 mmHg, secra78 24.80 - 26.38 inHg)ENGINE OVERHAUL Cynder block P) | Longe ow ; 7 ig | seat fg Aaparese an ont pete oe Grommet cover Timing ge eae cover ‘crank pulley — i (Pi) 204-324 zz Nem haem, fab) | Apply recommended seient {Wise genuine por KPB10-00250) cor equvaent 2 Koep in comact order, semmare EM-27ENGINE OVERHAUL —Disassembly PISTON AND CRANKSHAFT Remove oil filter, Place engine on work stand. Drain coolant and oil. Remove drive belts. Oy Pe eeNne |. Remove oil pan. . Remove crank pulley, i «vii Remove water pump. |. Remove timing gear case. on If the timing case is hard to remove due to liquid gasket, pry it off witha suitable too! at the cutout section. 10. © In-line pump Remove timer cover and timer.ENGINE OVERHAUL —Disassembly + VE-pump Remove injection pump gear. 11. Remove idler gear and idler gear shaft. 12, Remove camshaft gear, camshaft and valve lifters. 13, Remove oil pump assembly. 14, Remove crankshaft gear. 15, Remove flywheel and rear plate, 16. Remove connecting rod caps. 17. Remove pistons, EM-29ENGINE OVERHAUL —Disassembly Looten in numerical order. sees! 18, Remove rear oil seal retainer. 19. Remove bearing cap and crankshaft. Place the bearings and caps in their proper order.ENGINE OVERHAUL —Inspection and Replacement CYLINDER BLOCK DISTORTION If beyond the specified limit, replace i. OO Cylinder block distortion: Messing paint Standard — Less than 0.05 mm (0,0020 in) Limit 0.2 mm (0.008 in) CYLINDER LINER WEAR 1. Measure cylinder liner bore for out-of-round and taper with ‘a bore gauge, If beyond the limit, replace eylinder liner. ‘Standard inside diameter: ‘D238 89.000 - 89.030 mm (3.5039 - 3.5051 in) TD25 92.900 - 92.930 mm (3.6575 - 3.6587 in) TD27 and TD27T {96.000 - 96.030 mm (3.7795 - 3.7807 in) Refer to S.D.S. Wear limit: 0.20 mm (0.0079 in) (ut-of-round (X-Y) fim 0.020 mm (0.0008 in) Taper (A-B) limit: 0.20 mm (0.0079 in) 2. Check for scratches or seizure, If seizure is found, replace cylinder liner. Unies en ti) 3. Check amount of projection of cylinder liner. Cylinder finer projection: Standard 0.02 - 0.09 mm (0.0008 - 0.0035 in) Deviation of each cylinder: ‘Less than 0.05 mm (0.0020 in) CYLINDER LINER Replacement 1, Remove cylinder liner with Tool. EM-31ENGINE OVERHAUL —Inspection and Replacement 2. Install cylinder liner with Tool, ~ 3. Check amount of projection of eylinder liner. PISTON TO CYLINDER WALL CLEARANCE 1, Measure piston and cylinder bore diameter. Piston diameter “A: Refer to S.D.S. Measuring point “a” (Distance from the top): TD23 67 mm (2.64 in) TD25, TD27 and TO27T 70 mm (2.76 in) 2. Check that piston clearance is within the specification. Piston clearance: 0.05--0.07 mm (0.0020 - 0.0028 in} PISTON AND PISTON PIN CLEARANCE Check clearance between pistons and piston pins. » Clearance (A-B): ‘Standard: 0,008 to 0,007 mm (0.0003 to 0.0003 in} Limit Less than 0.1 mm (0.004 in)ENGINE OVERHAUL —Inspection and Replacement PISTON RING SIDE CLEARANCE Side clearance: Top ring 0.06 - 0.10 mm (0.0024 - 0.0039 in) 2nd ring 0,04 - 0.08 mm (0.0016 - 0.0031 in) Oil ring 0.02 - 0,06 mm (0.0008 - 0.0024 in) Max. limit of side clearance: Top 0.5 mm (0.020 in) 2nd 0.3 mm (0.012 in) oit 0.15 mm (0.0059 in) PISTON RING GAP ‘Standard ring gap: Top ring 0,30 - 0.45 mm (0.0118 - 2nd ring 1D23 and TO25 0.20 - 0.35 mm (0.0079 - 0.0138 in) ‘TD27 and TD27T 0.50 - 0.65 mm (0.0197 - 0.0256 in) Oiliring, 0.30 - 0.50 mm (0.0118 - 0.0197 in) Max, limit of ring gap> 15 mm (0.059 in) MAIN BEARING CLEARANCE ‘Main bearing clearance: Standard. 0.035 - 0.087 mm (0.0014 - 0.0034 in) Limit Less than 0.15 mm (0.0059 in) .0177 in) 1.0003 in) 1, Install main bearings to cylinder block and main bearing cap. 2, Install main bearing cap to cylinder block. Tighten all bolts in correct order and in two or three stages. 3, Measure inside diameter “A” of main bearing. sewn7as EM-33ENGINE OVERHAUL —Inspection and Replacement 4, Measure outside diameter “Dm” of main journal in cranl shaft seman 5. Calculate main bearing clearance. — Main bearing clearance = A ~ Om S Ney CONNECTING ROD BEARING CLEARANCE Connecting rod bearing clearance: ‘Standard 0,035 - 0.081 mm (0.0014 - 0.0032 in} Limit Less than 0.15 mm (0.0059 in) 1. Install connecting rod bearing to connecting rod and cap. 2, Install connecting rod cap to connecting rod. | / Apply oil to the thread portion of bolts and seating surface of nuts, 3, Measure inside diameter “A” of bearing. 4, Measure outside diameter “Dp” of pin journal in crankshaft, 5. Caleulate connecting rod bearing clearance. Connecting rod bearing clearance = A — Dp 'sews07A|ENGINE OVERHAUL —Inspection and Replacement CONNECTING ROD BEND AND TORSION Bend and torsion: Limit 0.05 mm (0.0020 in) ‘per 100 mm (3.94 in) length CONNECTING ROD SMALL END BUSHING CLEARANCE 1. Measure inside diameter "A" of connecting rod small end bushings. sem7s1s 2. Measure outside diameter "D" of piston pin. 3. Calculate connecting rod small end bushing clearance, Connecting rod small end bushing clearance = A ~ D Bushing clearance: Standard 0.025 - 0.045 mm (0.0010 - 0.0018 in) Limit 0.15 mm (0.0059 in) REPLACEMENT OF CONNECTING ROD SMALL END BUSHING 1. Drive in the small end bushing until itis flush with the end surface of the rod. Be sure to align the oil holes. 2. After driving in the small end bushing, ream the bushing. ‘Small end bushing inside diameter: Finished size: To23 [ ae SEMO6ZA 26,025 - 26,038 mm (1.0246 - 1.0251 in) ‘TD25 and TD27 28,025 - 28.038 mm (1.1033 - 1.1039 in) To27T 30.025 - 30.038 mm (1.1821 - 1.1826 in) EM-35,ENGINE OVERHAUL —Inspection and Replacement CRANKSHAFT Outetroumd XY 1. Check crankshaft journals and pins for score, bias, wear o 7 cracks. If faults are minor, correct with fine crocus cloth. a8 2. Check journals and pins with a micrometer for taper and out-of-round. Out of round (X-¥): Standard Less than 0.01 mm (0.0004 in) Limit ews 0.02 mm (0.0008 in) Taper (A-B): ‘Standard Less than 0.01 mm (0.0004 in) Limit 0.02 mm (0.0008 in) 3. Check crankshaft runout. Runout [T.1.R. (Total Indicator Reading)} Standard 0 - 0.03 mm (0 - 0.0012 in) Limit 0.10 mm (0.0039 in) seme RESURFACING OF CRANKSHAFT JOURNAL AND CRANK PIN When using undersize main bearings and connecting rod bearing the crankshaft journals or crank pins must be finished to m | * j 4 4 the bearings. R: Crank journal; 3.0 mm (0,118 in) OK «NG NG NG, Crank pin: 3.5 mm (0,138 in) CAUTION: © At thesame time make sure that the surface width does increase. © Do not attempt to cut counterweight of crankshaft.ENGINE OVERHAUL —Inspection and Replacement 58-60 mm (0.728-0.236in) (CRANKSHAFT PILOT BUSHING Crankshaft pilot bushing replacement 1. Pull out bushing with Tool. 2. Insert pilot bushing until distance between flange end and bushing is specified value. Distance: Approx. 5.8 - 6.0 mm (0.228 - 0.236 in) FLYWHEEL, RUNOUT Runout (Total indicator reading): Less than 0.15 mm (0.0059 in) FRONT PLATE Check front plate for warpage. If not within the limit, make flat or replace front plate. Warpage limit: 0.2 mm (0,008 in) EM-37ENGINE OVERHAUL —Inspection and Replacement ‘erhod A (Using ial supe) 2, Measure idler gear bushing inner diameter. 3. Calculate idler gear bushing clearance, IDLER GEAR END PLAY Measure idler gear end play between gear plate and gear. GEAR TRAIN Camshaft drive gear, injection pump drive gear, oil pump gea" idler gear and crankshaft gear 1. If gear tooth and key have scratches or are excessively worn] replace gear and key. 2. Check gear train backlash before disassembling and afte | assembling, Method A (Using dial gauge) Method B (Using fuse wire) If beyond the limit, replace gear. Backlash: Standard 0.07 - 0.11 mm (0.0028 - 0.0043 in) Limit 0.20 mm (0.0079 i IDLER GEAR BUSHING CLEARANCE 1, Measure idler gear shaft outer diameter. Bushing oil clearance: mets evi 0,025 - 0.061 mm {0.0010 - 0.0024 in) ad 0.20 mm (0.0079 in) Fe a Si Idler gear end play: Standard 0.03 - 0.14 mm (0.0012 - 0.0055 in) Limit Less than 0.3 mm (0.012 in)in) semssss| SsT1§243000 SeMaos5 REPLACEMENT OF IDLER GEAR BUSHING 1, Use a suitable too! to replace bushing, ler gear bushing. Finished si ‘42,00.- 42.02 mm (1.6535 - 1.6543 in) Idler gear shaft Install idler gear shaft so that oil hole of shaft faces upward. CAMSHAFT AND CAMSHAFT BUSHING ‘Camshaft bushing clearance Measure inside diameter of camshaft bushing and outside diameter of camshaft journal with a suitable gauge. Clearance between camshaft and bushing (A—B): Standard, 0.020 - 0.109 mm. {0.0008 - 0.0043 in) Limit ‘Less than 0.15 mm (0.0059 in) REPLACING CAMSHAFT BUSHING 1. Using Tool, remove camshaft bushings from the engine. Some bushings must be broken in order to remove. 2. Using Tool, install camshaft bushings as follows: (1) Install camshaft bushings in the order of “rear”, “4th”, "39d", “2nd” and “front. All bushings must be installed from the front. (2) Face the cutout upward and toward the front of the engine during installation, EM-39,ENGINE OVERHAUL —Inspection and Replacement (3) Rear camshaft bushing ‘Align the cutout of rear bushing with knock pin of replace bar before installation Insert rear bushing with replacer bar into the engine. Install guide plate with bolt holes (on the "TD" mark side facing upper side of cylinder block. Tighten bolts. Drive replacer bar until the alignment mark on replacer baf is aligned with the end of replacer guide. Remove replacer set. After installation, check that oil holes in camshaft bushings are aligned with ‘oil holes in cylinder block Alprvenesert to Aepacer br sre diver detarce pone @ Peels 29 oymane mack tne wea) surfaceENGINE OVERHAUL —Inspection and Replacement (4) 4th, 3rd and 2nd camshaft bushings Install in the same manner as rear camshaft bushing. ‘seweoxc (8) Front camshaft bushing Using 1st bushing adapter, position front camshaft bushing s0 that oil hole in cylinder block is aligned with oil hole in bushing 3. Check camshaft bushing clearance. —EM-41ENGINE OVERHAUL —Inspection and Replacement 4. Install new welch plug with a rit. Apply liquid seater. WS Laue sar oo When setting 4th through 2nd bushings on replacer ba ‘tape the bar to prevent movement. CAMSHAFT ALIGNMENT 1. Check camshaft journal and cam surface for bend, wear 0 damage. If fault is beyond limit, replace. 2. Check camshaft bend at center journal, If bend is greater than specified limit camshaft. Camshaft bend (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit Less than 0.06 mm (0.0024 in} repair or replat 3, Measure camshaft end play between locating plate and oe If beyond the specified limit, replace camsahift locating plat ‘Camshaft end play: Standard 0,08 - 0.28 mm (0,0031 - 0.0110 in) Limit Less than 0.5 mm (0.020 in) sewers}4. ENGINE OVERHAUL —Inspection and Replacement Measure camshaft cam height. If beyond the specified limit, replace camshaft. Cam height: ‘Standard Intake 41.733 mm (1.6430 in) Exhaust 41.900 mm (1.6496 in) Limit Intake Less than 41.20 mm (1.6220 in) Exhaust ‘Loss than 41.40 mm (1.6299 in) EM-43ENGINE OVERHAUL —Assembly <= test yee combustion chamber Grade mark {het iretion) Matching mark {Cylinder No.) semsr26 sewoae| [Ring S80 HEEION o> ond i ving PISTON Assemble pistons, piston pins, snap rings and connecting rods. a. Numbers are stamped on the connecting rod and cap o sponding to each cylinder. Care should be taken to avci ‘wrong combination including bearing. b, When inserting piston pin in connecting rod, heat p with a heater or hot water [approximately 60 to 70°C (1 to 158°F)] and apply engine oil to pin and small end of co necting rod. After assembling, ascertain that piston swings smoothly. Install piston assembly. CAUTION: a. Stretch the piston rings only enough to fit them in th piston grooves. b, Be sure the manufacturer's mark faces upward. cc. Install No. 1 piston ring in such a way that its gap. faces direction of the. piston pin; and then install piston rings ‘that their gap positioned at 180” to one another. (CRANKSHAFT 1. Install crankshaft, (1) Set main bearings in the proper position on cylinder block. ‘a. If either crankshaft, cylinder block or main bearing is reus again, it is necessary to measure main bearing clearance, b. Upper: bearings have oil hole and oil groove, however bearings do not.ENGINE OVERHAUL —Assembly “Tannin numerical order (2) Apply engine oil to crankshaft journal and pin and install crankshaft. (3) install main bearing caps. 1a} Install main bearing cap with the number facing the front of vehicle. b) Apply engine oil to main bearing cap and cylinder block contact surfaces, ‘c) Install rear oil seal assembly. Apply engine oi! to contact surface of rear end oil seal and crankshaft. (4) Install crankshaft. thrust washer at the 4th journal from from, Install thrust washer so that oil groove can face crankshaft. (6) Tighten bearing cap bolts gradually in stages, starting from two to three separate stages, from center bearing and moving ‘outward in sequence, (6) Measure crankshaft free end play at No, 4 bearing, Crankshaft free end play: Standard, (0.055 - 0.140 mm (0.0022 - 0.0055 in) Limit 0.4 mm (0.016 in) If beyond the limit, replace No. 4 main bearing thrust washer. Refer to S.D.S. EM-45ENGINE OVERHAUL —Assembly Front Mac semesa| | Pn Corantehatt year 2. Install pistons with connecting rods. (1) Install them into corresponding cylinder using Tool, * Be carefulinot to scratch cylinder wall with connecting rod, Apply engine oil to cylinder walt, piston and bearing. © The leaf type combustion chamber on piston head must b at right side of engine. (2) install connecting rod bearing caps. 3, Measure connecting rod side clearance, Connecting rod side clearance; ‘Standard 0.10 - 0.22 mm (0,0039 - 0.0087 in) Limit (0.22 mm (0.0087 in) If beyond the limit, replace connecting rod and/or crankshaft, GEAR TRAIN 1. Set No. 1 piston at its top dead center. 2. Align each gear mark and install gears.‘Laud gosker semes2e semesse, ENGINE OVERHAUL —Assembly TIMING GEAR CASE Installation 1. Before installing timing gear case, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of front plate. 2. Apply a continuous bead of liquid gasket to mating surface of timing gear case, ¢ Be sure liquid gasket is 2.5 to 3.5 mm (0.098 to 0.138 in) wide, '* Attach timing gear case to front plate within 10 minutes after coating. ‘+ Wait at least 30 minutes before refilling engine coolant or starting engine. ‘¢ Use Genuine Liquid Gasket or equivalent. —EM-47SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment COMPRESSION PRESSURE Unit: Pe tat, kalem?, prom Valve guide ‘Sondad [Sone Sood 2942 (20.4, 30, 42717200 - 7 209. 12048 ‘nino 2a82 (5,25, 36817200 ‘vive evsteamece | “oaat a 7 - 0.4742) tee i be esta ori ‘Valve que inner diameter ‘800-8.016 CYLINDER HEAD Unit me Gn) iniaded sizer pelea Stender Umi snderpenvave gga nove [2200-12011 Set it rine vate aitete |e - aston ameter 0.4729) Head surface datortion ane te, 0.210.006) Ne (0022-0084 Nomina ovinderheedwaht 999-00: (3599-8847) Notertceoce fi of vate guide (0.0009 0.00171 dart [Ma 0 VALVE Units“ mm (od os Ls TTiMargin mikes Soom pierce 0023-0089 torake ‘o.0005- {0.15 (0.06 le 0002) 006-007 Exhaust (o0018- | 020 (000 0.0028), 8 ‘ave aefiton int tnake 0.30 (00178) Y seme Exhaust 0.40 100157) Engine 027 ond en tors | tozs | TO? a Valve spring - Free enath ‘om fn) Vat sd dame Painted ro 52.15 (20531) 299-403 [anaes | 404.406 Foxake cisn- | tiga0- | 4708 Painted yeion 980 2087) ss7a) | tesa) | 1717) resis eight 349-363 [369.973 [379-981 oN Umm, exhaust (isre | tnasas | t1492 923/6728-759.1 sea) | tas | 1007 Pita eed (2.3/688-77.4, s27ans1 3-170. ‘Valve erat" Iovate 318/697.3-7787 v7 461) Painted yin s1g711-795, ' Sane 1252/1868 - 175.3) Valve wom ameter" aaabei ag Tnsake 7:962-7877 (0.3135 -03141) ret (mm, int) mee s2me73-3308 Eomos 7545 7.960 (03128-03198) stendard (42.3728.3- 333 Votre sat nai" 1.905/688 74.3) ncaa . - 4237707 = ah v (22.3278, 1886/609) Vaive morgan 7010086) Out of sqvere ve 2.010079) ‘Vive wem end surface —— ving tiie 0210.08) "Valve cerance (Hot) 0.38 (0.0198) Exteust —M-48SERVICE DATA AND SPECIFICATIONS (S.D.S.) VE LIFTER AND PUSH ROD: Inspection and Adjustment (Cont‘d) CYLINDER HEAD TO VALVE DISTANCE 2 ee Ea eS. ae eae oe Mwonwraoneer Poe] - Can inseas = Maroon POH 26O88) 3186) bE =— oe (0.0012- | 0.20 (0.0079) - : ost ; mie = mune esa eewrnte Bee Rte my osea | 28 : ‘Standard ‘Limit "I tes rns ae oa ey sr shaft and rocker arm take 10.0108 - 0.0266) | ‘25 (0.0492) ou toma| Oe ‘Standord | _ imi on toor20-0027— | 125 '0.0482) a ‘aaTo 2080 ae star diameter (0.7866 ~ 8 ; cen ; sano | tan 1 epee band FTAA) (0-0,0039) | 0.30(0.0118) a = se Fe sae ere Smet conned 531) rain ear (0.0008- | 0.15 (0.0059) eae oer rei iar a te sos ar ; ay 7 Seon 7 EM-49SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) Valve seat itm tl senosse 1023 1025 027 ana TO27T fake ‘ 41.098 41.068 42.895 42545, 44595 44565 Ouer damete “0, (16185-16189) (1.9746 1.6750) (1.7555 1.7837 inner diameter" ‘349-960 11374-1082) | 964-36600455. 1440) | 984-986 (612- 1520) Diemer of sat “0,” 3e9-29 (1591-1590) | a04-a06 1ser 1898) | 424-426 1669-1677) “41,000.47 015 2500. 02538 “a4s00. 4455 liner head valve sat diameter (uote 16148) (19732.1.9738) (1.7820 1.7526 ‘Vates watfoe ana "0 a9" 91" wor wor Gt Exhaust ‘Outer diameter "0," casts 38.538. 36.545 98595. 38.545 39.596. 39.545 2 (14384 14988) (5179-15175) 115565 1.5569), ‘ 36:98. 96.748 38.795 98746 39.795 39.745 (0:2 (2.006) Oven (Seve (14463-14467) (15250. 15254) 5508. 1.5548) 36035-36948 38995 38.048 39.936 39.945, CORIO" Seapt leaees? (14541 1.545) #15529. 1.53039 (15722. 18720 324-331 294-201 24-34 wa | eee {noe diameter," : (1987 -1.185) 1238-1280) vom | m9 in 64.286 -1300) JE Totake Charatr of "0," 3390-9810 3890-36:10 36.90-37.10 hau ~ 2 (13346-13428) (ara (14528-14608) tinder head aie seat ciometer — 36.495 36 510 38.495..38510 29.488-39510 soto (14368 14374) (sts 1516) 115549. 1 85554 36.695 96.770 33.605.98710 739.695-39.710 92 10906) Oveniee (14447 1.4459) (5204-15240) (1.5628 -1 5638) 36.895 36.970 38805-28910 39.805 -39910 6.4 10ME1 Ores, (14526-14851) (3531315919) (18707-13713) Vole wat ave angle "6 ae 90" a0 aa 00"; SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) |AFT AND CAMSHAFT BEARING Bem Unit: men tin) ‘Stendara imi journal 0.020: 0.109 sou 10g 2.108 | 0.18 0.0059) 50.740 1.39761 - 5, 50501-50560 . (1.9890: 1.9698) Dart, 50.321 50.340 - (19611 1.9610) ea 30.121 60.140 7 7597) : (19733-19740) 21820) é ‘9.71 49.900 7 (19654-19661) 39.1677 bend (Tet! eather 7 1316 ) 0.02 (0.0008 | .0640.0024) 7526) 008-028 ° f 7 F erdoiey —_[roaoat-oorr | 050100197) 1545 3509) ; tas 548) vous e 37261 ¥a31 E 521.308) : ‘Sanderd ini yas ionerar 5.1300) 41733 1.6420) | 41.2011.62201 10 hat “4190017 6006) | 41.40 7.6209) 4606) is10, : 3555) ie 5034) ‘910 s713) @ EM-51SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) CYLINDER BLOCK AND CYLINDER LINER. 20 10.79) 0 Bs " E Front c yA TNL sem9s0e 023 T0258 ‘To27 and 1077 ‘Nominal eyiner block neat Hemet orgs 54.95 96.05 12.1634. 2.1673) Surface gress Without eylingr line) ‘Standard ‘Les than 0.05 (0.00201 Gi 02 (0.008) Cylinder bore Taner ameter Standard 92.000 92.020 95,900..95.920 99,000 -99.020 me (6220 - 3.6722) (3:7786-3.7764) (38976-35884) ‘Cylinder bore (With eytinaer Tne} nner dimeter ‘stance 29,000 -89.010 92,900-92.910 26.000-36.010 Grate sod (2.5099 - 3.5043) (9.0575 3.579) (8.7795 3.7198) ain 9,010 69.020 ‘92.910-92.920 ‘96.010 96.020 Ee (3.8043 -3.5047) (3.5579 -3 6583) (@.7799-3,7803) ar "29.020 69.030 92920-92930 96.020 -98.090 (9.5047 3.5051) (0.9503 3.6587) (0.7803 3.7807) Wear ini (0.20 10.0078) Ourofeound (x YI ‘ese ta 0.020 (0.0008) ‘Tope (A= 8) ‘set 0:20 (0.0079) Projection "3" (0.02 0.08 (0.0008 - 0.0935) Ovid ofeach evtinder ‘Lee than 0.05 (0.00204 Joverferencs ft eyindor line 1 Block 9.01 #0 0.03 (-0,0008 to 0.0012),SERVICE DATA AND SPECIFICATIONS (S.D.S.} Inspection and Adjustment (Cont'd) Unies i) > aa07) : oe eee aa | at ‘ i ra 788 =e pretence ete aon | mame | sos.esso cr sme) a ae oe awe | samme | owes arm-anen anced | Tastee, || aataes | at me Tis Tam aOR EM-53SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont‘d) CONNECTING ROD Piston ring nit: em to Standard Umit ‘Sie clearance 0.08-0:10 Top ones. eae) | °5910.0197) 004-008 aed oat 388 | 020 0.0188) 902-008, ou (oar 388 | 0.18 (0.00501 ing a0 = 020-045 ee (oorts 0.0177) 020-0. "028,728 | ooo79-0.0138), 2nd 1.5 (0.058), 050-085, 7027, 7027T | igor97 -0.0288) i 020-050 Siena a (00118 0.0197) Piston pin nit: tind ‘TO8 and ors | T2594 | roar Piston pin outer diameter 25993. | 77993. | 20999 26.000 | 28.900 | 20.000 (ozs | 1.t021- | 1808 - 0296) { 1.1024 | 13811) Piston pin to piston clearance Piston pin to connecting 06 clearance Standart 0.008 0 0.007 (-0.0008 1 0.0003), 0.025 -0.045 (0.0010 - 0.0018) 0.15 10-0058) TD26 and rors | 725 = 169.975. ae 159.025 | 186.975 -167.025, (e.2588- | (6.1801 -6.1821), 8.2608) Bend, torsion (per 100 (3:94)) tii 0.05 (0.0020) Piston pin bore dia, ‘Side ciarance Stondars Gi 26.025, 26038 (1.0246 - 10281) 0.10 -0.22 (0.0039 0.0087) (0.22 0.0087)SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) Unite in) AVAILABLE MAIN BEARING 0.40 (0.0157 EM-55 Bearing clearance Unit: mm tind ‘Main bearing clesrance Standeret (0035 0.087 (0.0014 0.0034) Limit 0.15 (0.0058) ‘Connecting rod bearing narance ‘Standard 6.095: 0.081 (0.0014 0.0082), Limit 0.18 (0.0089) ‘Main bearing und SEMTO0A ots me fo) 70807-70520 ‘Crank journal diameter (27016-27821) — Standard 70.807 -70:920 (2.7916 - 2.7921) 52913-52928 Undersize (2.0832 - 2.0837) (0.25 (0.0008), 170857 - 70.670 (2.7818 2.7829) 56913-86962 (050 (0.0197) 70.407 - 70.420 (2.7798 -2.7728) (2.2407 22428) | eee -———__—____ 0.75 (0.0298) 70157 - 70.470 (2.7621 - 2.7626) 46.00 (1.8110) ——— (0.0904 69.907 - 69.920 (2.7522 - 2.7628) A 8 AVAILABLE CONNECTING ROD BEARING ‘Connecting rod bearing undersize 7 emnns : Gaiaaieeiiiamcmaas ‘rank pin journal diameter 2.01 (0.0004) 7025, 1027 and fen err ae ‘yo23 SHE (0.02 (0.0008) 5 52913-52926 | 66913-96926 sont (2.0832-2.0837) | (2.2407 -2:2412) 2.0% (0.0004) Undersize 1s woe 52.663-52.676 | 90.669-56,678 2.02 (0.0008) (0.26 (0.0008) (2.0733. 2.0738) | (2:2908-2.2312) 52.413. 52.426 | 96413-56675 9-008 (0-0.9013) Gea tent (2.0635 - 2.0640) | 2.2210-2.2313) 0.10 (0.0038) 52.163-62.176 | 56.169- 86.176 = 75 (o-oae6) (20837-20542) | 22111-22136) loneaco.1¢ iopnag 0.20) ‘siai3-51.926 | 65913-55976 pe (2.0428 - 2.0443) | (2.2013- 2.2018)SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) AVAILABLE THRUST WASHER MISCELLANEOUS COMPONENTS ‘Thrust washer undersize Ciera, SEE Ret aaales | anton norefame Ss scm otoen ew | a aad Standard » i ee Se a OO Re rt 5 [can amo poms ane Rea Te cea rue <[etanponeeond tonne — a zion) ; re aus 2mm are ome conse e762 0 OT Engine outer parts Engine parts oe a= i ee aan Megat a7] gaa sa wip, iran, iim, | SRR ae wes a om a 25-29 25-30 18-22 Crank pulley nut 294-324 90-93. 27s stg 20-24 20-88 zeta fern att nena Ee eerrene oal teat tani ‘Exhaust outlet nut 17-23, 47-230 12-17 ‘Timing goor case out 18-21 16921 1215 rae, Eoccpeon, ia Jaa! iuesinpronn 2-88 20-25 418s Gmmmngwnet, te abean a Iieionpemptotntet «131-42 22-2 comtcamgue ce omen aot oe bolt injertho.saznie w: 04-04. 55-65 40-47 Adler gear shaft bolt. 2 26-36 19-26 elindr hess ea aa eae a Gaeat ee Injection pump drive 69-69 60-70 43-51 * ee ‘eer en Vietonnefoemt 20-25 20-25 We1p_ «interno rion oie Simmenmenmn 9.09 30-4) 2 Glows Se ae fenmoraaareet steal atcaa may Raeanitbndetnt 20-25 20-28 tk feciceee Mikal lt Gea | maga eo sco) a bar bott Rocker cover serew 4-2 04-02 07-14 : tomers wit, apes wi mas Gemeretme 25-29 2-29 18-22 Pe eae es, a or exhaust manifold side) EGR. vale bolt ye-21 16-24 12-18