Chapter 2 SERVICE DATA

1. Maintenance service data ....................................................................................... 2-3

1.1 Engine general ......................................................................................................................... 2-3
1.2 Basic engine ............................................................................................................................. 2-4
1.3 Fuel system .............................................................................................................................. 2-7
1.4 Lubrication system.................................................................................................................... 2-7
1.5 Cooling system ......................................................................................................................... 2-7
1.6 Inlet and exhaust system .......................................................................................................... 2-7
1.7 Electrical system....................................................................................................................... 2-8
2. Tightening torque table........................................................................................... 2-9
2.1 Basic engine ............................................................................................................................. 2-9
2.2 Fuel system .............................................................................................................................. 2-9
2.3 Lubrication system.................................................................................................................. 2-10
2.4 Cooling system ....................................................................................................................... 2-10
2.5 Inlet and exhaust system ........................................................................................................ 2-10
2.6 Electrical system..................................................................................................................... 2-10
2.7 Standard bolt and nut tightening torque ................................................................................. 2-11
2.8 Standard stud tightening torque ............................................................................................. 2-11

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 Chapter 2 SERVICE DATA

1. Maintenance service data

Chapter 2 SERVICE DATA

1.1 Engine general

Unit: mm [in.]
Item Nominal Standard Limit Remarks
Maximum rotation speed (No-load) 2550 min-1 2500 to 2550 min-1
Minimum rotation speed (No-load) 820 min-1 720 to 820 min-1
Faulty if lower or
3.2 MPa
2.8 MPa When oil and water temperatures
Compression pressure (at 300 min-1) {33 kgf/cm2}
{29 kgf/cm2} at 20 to 30 °C [68 to 86 °F]
[469 psi] or more
[412 psi] or less
Faulty if lower or
0.3 to 0.5 MPa
Rotated speed 0.15 MPa
{3 to 5 kgf/cm2}
at 1500 min-1 {1.5 kgf/cm2}
[43 to 71 psi] When oil temperatures
Engine oil pressure [21 psi] or less
at 60 to 70°C [140 to 158°F]
0.10 MPa 0.05 MPa
Idling speed {1.0 kgf/cm2} {0.5 kgf/cm2}
[14 psi] or more [7 psi]
Inlet opens BTDC 30°
Inlet closes ABDC 50° Values are only for checking
Valve timing valve timing and are different
Exhaust opens BBDC 74° from the actual ones.
Exhaust closes ATDC 30°
Inlet 0.25 [0.0098]
Valve clearance When cold
Exhaust 0.25 [0.0098]
Fuel injection timing BTDC 5°

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Chapter 2 SERVICE DATA

1.2 Basic engine

Unit: mm [in.]
Item Nominal Standard Limit Remarks
ø19 19.010 to 19.030
Rocker bushing inside diameter
[0.75] [0.7484 to 0.7492]
ø19 18.980 to 19.000
Rockers Rocker shaft outside diameter
[0.75] [0.7472 to 0.7480]
0.010 to 0.050 0.070
Clearance between rocker bushing and shaft
[0.0004 to 0.0020] [0.0028]
ø8 7.940 to 7.955 7.900
Inlet
Valve stem [0.31] [0.3126 to 0.3132] [0.3110]
Outside diameter ø8 7.920 to 7.940 7.850
Exhaust
[0.31] [0.3118 to 0.3126] [0.3091]
Valve and 0.065 to 0.095 0.150
Inlet
valve guide Clearance between [0.0026 to 0.0037] [0.0059]
valve stem and guide 0.080 to 0.115 0.200
Exhaust
[0.0031 to 0.0045] [0.0079]
14 13.9 to 14.1
Valve guide mounting length
[0.55] [0.547 to 0.555]
Valve seat angle 30°
0.4 0.3 to 0.5 1.0
Inlet
[0.016] [0.012 to 0.020] [0.039] Seat width
Valve sinkage
0.5 0.4 to 0.6 1.0
Exhaust
Valve seat and [0.020] [0.016 to 0.024] [0.039]
valve
1.4 1.26 to 1.54 1.8
Seat width Valve Valve
[0.055] [0.0496 to 0.0606] [0.071] Valve sinkage margin
seat angle
Refacing
2.13
Valve margin permissible up to
[0.0839]
1.83 [0.0720]
48.85 47.60
Free length
[1.9232] [1.8740]
A=1.5°or less A
B=1.3 [0.051] B
B = 1.5 [0.059]
Squareness or less
at the end Lf
Valve spring Lf = 48.85
[1.9232]
43 mm [1.69 in.]/ 43 mm [1.69 in.]/
176 to 196 N 147 N
Set length/load
{18 to 20 kgf} {15 kgf}
[39 to 40 lbf] [33 lbf]
TIR (dial gauge reading)
0.6 when pushrod is supported
Push rod Runout
[0.024] along center line of spheri-
cal surface at either end.
0.05 0.20
Distortion of bottom surface Reface slightly.
[0.0020] or less [0.0079]
Cylinder head
1.2 1.15 to 1.25
Compressed thickness of gasket
[0.047] [0.0453 to 0.0492]
Repair limit:
ø94 94.000 to 94.035 94.200 [3.7087]
Inside diameter Refinish cylinder to 0.25
[3.70] [3.7008 to 3.7022] Service limit:
[0.0098] or 0.50 [0.0197]
94.700 [3.7283]
oversize of nominal value by
Cylinder
0.01 honing.
Roundness
[0.0004] or less Use oversize piston and pis-
ton ring.
0.015
Cylindricity
[0.0006] or less

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 Chapter 2 SERVICE DATA

Unit: mm [in.]
Item Nominal Standard Limit Remarks
93.955 to 93.985 93.770
Standard
[3.6990 to 3.7002] [3.6917]
Outside diameter +0.25 [0.0098] ø 94 94.205 to 94.235 94.020
(at piston skirt) Oversize [3.70] [3.7089 to 3.7100] [3.7016]
+0.50 [0.0197] 94.455 to 94.485 94.270
Piston
Oversize [3.7187 to 3.7199] [3.7114]
-0.25 to 0.15
Protrusion from crankcase
[-0.0098 to 0.0059]
5g
Weight difference in one engine
[0.2 oz.] or less
No.1 0.30 to 0.50 1.50
compression [0.0118 to 0.0197] [0.0591]
Piston No.2 0.50 to 0.70 1.50
Piston ring end gap
ring compression [0.0197 to 0.0276] [0.0591]
0.30 to 0.50 1.50
Oil
[0.0118 to 0.0197] [0.0591]
ø30 29.994 to 30.000
Outside diameter
[1.18] [1.1809 to 1.1811]
Piston 0.000 to 0.016 0.050
Clearance between piston
pin [0.0000 to 0.0006] [0.0020]
0.020 to 0.091 0.120
Clearance between connecting rod bushing
[0.0008 to 0.0036] [0.0047]
ø30 30.020 to 30.045
Bushing inside diameter
[1.18] [1.1819 to 1.1829]
0.05/100
0.15/100
Connecting rod bend and twist [0.0020/3.94]
[0.0059/3.94]
or less
Use undersize connecting
Connecting rod Clearance between crankpin and connecting 0.030 to 0.090 0.200 rod bearing when the limit is
rod bearing (oil clearance) [0.0012 to 0.0035] [0.0079] exceeded replacing with
standard size bearing.
0.15 to 0.35 0.50
End play Replace connecting rod.
[0.0059 to 0.0138] [0.0197]
Weight difference of connecting rod 10 g
assembly in one engine [0.35 oz.] or less
0.15 0.50
Flatness
[0.0059] or less [0.0197]
Flywheel
0.15 0.50
Runout
[0.0059] or less [0.0197]
0.5 1.5
Outer circumference face runout Replace with new one when
[0.020] or less [0.0591]
Damper engine is operated for 8000
0.5 1.5 hours
Outer circumference radial runout
[0.020] or less [0.0591]
0.04 0.10
Runout TIR
[0.0016] or less [0.0039]
6.684 6.384 to 6.784 6.184
Inlet
[0.2631] [0.2513 to 0.2671] [0.2435]
Cam lift
6.720 6.420 to 6.820 6.220
Exhaust
[0.2646] [0.2528 to 0.2685] [0.2449]
ø54 53.94 to 53.96 53.90
Camshaft No.1, 2, 3
[2.13] [2.1236 to 2.1244] [2.1220]
Journal diameter
ø53 52.94 to 52.96 52.90
No.4
[2.09] [2.0842 to 2.0850] [2.0827]
Clearance between camshaft journal and 0.040 to 0.090 0.15
camshaft bushing [0.0016 to 0.0035] [0.0059]
0.10 to 0.25 0.30
Camshaft end play Replace thrust plate.
[0.0039 to 0.0098] [0.0118]

2-5
Chapter 2 SERVICE DATA

Unit: mm [in.]
Item Nominal Standard Limit Remarks
0.009 to 0.050 0.100
Clearance between bushing and shaft
[0.0004 to 0.0020] [0.0039]
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
[0.0020 to 0.0079] [0.0138]
Interference between shaft and crankcase 0.035 to 0.076
hole [0.0014 to 0.0030]
0.05 to 0.15 0.25
Timing gear backlash Replace gears
[0.0020 to 0.0059] [0.0098]
77.850 [3.0650]
ø78 77.955 to 77.970 (Repair)
Crankshaft journal outside diameter
[3.07] [3.0691 to 3.0697] 77.100 [3.0354]
(Replace)
ø58 57.955 to 57.970 57.800
Crankpin outside diameter
[2.28] [2.2817 to 2.2823] [2.2756]
Pin maximum
defection:
Parallelism of journal and crankpin
0.01
[0.0004] or less.
0.01 0.03
Crankshaft Circularity of journal and crankpin
[0.0004] or less [0.0012]
0.01 0.03
Cylindricity of journal and crankpin
[0.0004] or less [0.0012]
R3 2.8 to 3.2
Fillet radius of pin and journal
[0.12] [0.110 to 0.126]
0.04 0.10
Runout TIR
[0.0016] or less [0.0039]
Use oversize thrust plate
0.100 to 0.264 0.300 when the limit is exceeded
End play
[0.0039 to 0.0104] [0.0118] replacing with standard size
thrust plate.
Use undersize main bearing
0.050 to 0.110 0.200 when limit is exceeded
Main bearing Clearance between crank journal
[0.0020 to 0.0043] [0.0079] replacing with standard size
bearing.
0.05 0.20
Distortion of top surface Reface slightly.
[0.0020] or less [0.0079]
14.000 to 14.018 14.100
Crankcase Tappet guide hole inside diameter
[0.5512 to 0.5519] [0.5551]
Clearance between tappet and tappet guide 0.016 to 0.052 0.08 Replace a tappet until the
hole [0.0006 to 0.0020] [0.0031] clearance reaches the limit.

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 Chapter 2 SERVICE DATA

1.3 Fuel system

Item Nominal Standard Limit Remarks
Make shim adjustment.
11.77 MPa 11.77 to 12.75 MPa Pressure varies by 1 MPa
Injection start
{120 kgf/cm²} {120 to 130 kgf/cm²} {10 kgf/cm²}
pressure
[1707 psi] [1707 to 1849 psi] [144 psi] per 0.1 [0.004]
thickness of shim.
Fuel
injection Check nozzle with a hand
nozzle tester (at fuel oil tempera-
ture 20°C [68°F]).
Spray angle 0° Replace the nozzle tip if
the spray pattern is still
bad after washing in clean
fuel oil.

1.4 Lubrication system

Unit: mm [in.]
Item Nominal Standard Limit Remarks
Clearance between outer rotor and pump 0.20 to 0.30 0.50
Replace pump assembly.
case [0.0079 to 0.0118] [0.0197]
ø16 15.985 to 16.000
Shaft outside diameter (between case)
[0.63] [0.6293 to 0.6299]
Shaft outside diameter ø14 13.957 to 13.975
(oil pump bushing side) [0.55] [0.5495 to 0.5502]
0.032 to 0.074 0.150 Replace pump case
Oil pump Clearance between shaft and pump case
[0.0013 to 0.0029] [0.0059] or pump assembly.
Clearance between shaft and oil pump 0.025 to 0.111 0.200 Replace pump bushing
bushing [0.0010 to 0.0044] [0.0079] or pump assembly.
Clearance between inner rotor and outer 0.13 to 0.15 0.20 Replace outer rotor
rotor [0.0051 to 0.0059] [0.0079] and shaft assembly.
0.04 to 0.09 0.15
End play of rotor and pump case Replace pump assembly.
[0.0016 to 0.0035] [0.0059]
0.35 MPa 0.35 ± 0.05 MPa
Relief valve Valve opening pressure {3.5 kgf/cm²} {3.5 ± 0.5 kgf/cm²}
[50 psi] [50 ± 7.1 psi]

1.5 Cooling system

Item Nominal Standard Limit Remarks
76.5°C
Temperature for opening 76.5 ± 2°C [169.7 ± 3.6°F]
[169.7°F]
Thermostat
Temperature at which valve lift becomes 9
90°C [194°F]
mm [0.31 in.] or more

1.6 Inlet and exhaust system

Item Nominal Standard Limit Remarks
0.2 mm [0.008 in.] Repair by grinding or
Exhaust manifold distortion
or less replace.

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Chapter 2 SERVICE DATA

1.7 Electrical system

Unit: mm [in.]
Item Nominal Standard Limit Remarks
ø32 31.4
Outside diameter Replace
[1.2598] [1.2362]
0.10
Commutator Runout - Repair or replace.
[0.0039]
0.2
Undercut depth - Repair
[0.0079]
18 11
Starter Brush length Replace
[0.7087] [0.4331]
34 N 29.2 to 39.4 N 13.7 N
Pressure of brush springs {3.5 kgf} {3.0 to 4.0 kgf} {1.4 kgf} Replace
[25 lbf] [21.53 to 29.06 lbf] [10 lbf]
Voltage 11 V -
Nonload
Current 180 A or less - Inspection
characteristics
Rotational speed 3800 min-1 or more -
1500 or less -
Rotational
Output current
speed 2500 or less 33 A or more Inspection
(When heated)
(min-1)
5000 or less 47 A or more
A007TA
0483A Regulator adjusting voltage 14.7 ± 0.3 V at 20°C [68°F]
18.5 5.0
Brush length Replace
[0.7283] [0.1969]
Resistance between slip rings 2.7 to 3.2 Ω
1500 or less -
Rotational
Output current
speed 2500 or less 16 A or more Inspection
(When heated)
(min-1)
5000 or less 21 A or more
A002TA
Alternator Regulator adjusting voltage 14.7 ± 0.3 V at 20°C [68°F]
7871
18.5 5.0
Brush length Replace
[0.7283] [0.1969]
Resistance between slip rings 13.6 to 15.9 Ω
1500 or less 24A or more
Rotational
Output current
speed 2500 or less 53 A or more Inspection
(When heated)
(min-1)
5000 or less 71 A or more
A005TA
5083A Regulator adjusting voltage 14.7 ± 0.3 V at 20°C [68°F]
18.5 5.0
Brush length Replace
[0.7283] [0.1969]
Resistance between slip rings 2.4 to 2.9 Ω
Rated voltage DC 10.5 V
Glow plug
Current 9.7 ± 1.0 A
Rated voltage 12 V
Magnetic valve
Resistance 8Ω
When center of belt
12
V-belt tension Deflection pressed at approx. 98 N
[0.4724]
{10 kgf} [22 lbf]

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 Chapter 2 SERVICE DATA

2. Tightening torque table

2.1 Basic engine
Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft

Cylinder head 12 × 1.75 118 ± 5 12 ± 0.5 87 ± 3.6

Cylinder head plug 16 × 1.5 44.1 ± 5 4.5 ± 0.5 33 ± 3.6
Rocker cover 8 × 1.25 11.5 ± 1.5 1.15 ± 0.15 8.5 ± 1.1
Rocker shaft bracket bolt (long) 8 × 1.25 17.2 ± 2.45 1.75 ± 0.2 12.9 ± 1.8
Main bearing cap 14 × 2.0 103 ± 5 10.5 ± 0.5 76 ± 3.6
Connecting rod cap 10 × 1.25 54 ± 5 5.5 ± 0.5 40 ± 3.6
Flywheel 12 × 1.25 83 ± 5 8.5 ± 0.5 61 ± 3.6
Camshaft thrust plate 8 × 1.25 11.5 ± 1.5 1.15 ± 0.15 8.3 ± 1.1
Front plate 8 × 1.25 11.5 ± 1.5 1.15 ± 0.15 8.3 ± 1.1
Timing gear case 8 × 1.25 18.5 ± 1.5 1.9 ± 0.1 13.4 ± 1.1
Crankshaft pulley 30 × 1.5 490 ± 10 50 ± 1 361 ± 7.3
Idler thrust plate 10 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Rear plate 10 × 1.25 55.9 ± 5.8 5.7 ± 0.5 41.2 ± 3.6
Rocker adjusting nut 8 × 1.25 20 ± 2 2 ± 0.2 15 ± 1.4

2.2 Fuel system

Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft

Fuel injection nozzle (engine) 20 × 1.5 58.9 ± 5.8 6 ± 0.5 43 ± 4.3

Fuel injection nozzle retaining nut 16 × 0.75 36.8 ± 2.4 3.8 ± 0.2 27.1 ± 1.8
Fuel injection pump gear 12 × 1.75 59.5 ± 0.5 6.1 ± 0.05 43.9 ± 0.37
Fuel injection pump overflow valve - 24.5 ± 4.5 2.5 ± 0.46 18 ± 3.3
Fuel injection pipe nut 12 × 1.5 29.5 ± 2.9 3 ± 0.3 21.8 ± 2.14
Fuel return pipe nut 10 × 1.25 19.7 ± 1.9 2 ± 0.1 14.5 ± 1.4
Fuel filter drain plug 14 × 1.0 1.1 ± 0.3 0.1 ± 0.03 0.8 ± 0.22
Fuel filter cartridge 20 × 1.5 13.5 ± 1.5 1.4 ± 0.1 10 ± 1.1
Fuel filter water level sensor assembly 36 × 1.5 13.5 ± 1.5 1.4 ± 0.1 10 ± 1.1
Fuel leak-off pipe mounting nut 12 × 1.5 22.6 ± 1.9 2.3 ± 0.1 16.7 ± 1.4

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Chapter 2 SERVICE DATA

2.3 Lubrication system

Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft

Oil pan 8 × 1.25 11.5 ± 1.5 1.2 ± 0.1 8.3 ± 1.1

Oil pan drain plug 20 × 1.5 78 ± 5 8 ± 0.5 57 ± 3.7
Oil pump gear 10 × 1.25 33 ± 5 3.4 ± 0.5 24 ± 3.7
Relief valve 22 × 1.5 49 ± 4.9 5 ± 0.5 36 ± 3.7
Relief valve plug 18 × 1.5 44 ± 4.9 4.5 ± 0.5 32.5 ± 3.6

2.4 Cooling system

Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft

Thermostat case 8 × 1.25 18.5 ± 1.5 1.9 ± 0.1 13.6 ± 1.1

Water drain plug 1/4-18NPSF 39.2 ± 3.9 4 ± 0.3 28.9 ± 2.8
Water pump mounting bolt
8 × 1.25 9.8 ± 1 1 ± 0.1 7.2 ± 0.7
(tightening with water pump case cover)
Water pump mounting bolt
8 × 1.25 18.2 ± 3.4 1.9 ± 0.3 13.4 ± 2.5
(tightening with crankcase)
Water pump plug R3/8 31.9 ± 2.4 3.3 ± 0.2 23.5 ± 1.8

2.5 Inlet and exhaust system

Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft

Exhaust manifold (bolt only) 8 × 1.25 18.5 ± 3.5 1.9 ± 0.3 13.6 ± 2.5

2.6 Electrical system

Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft
+2 +0.2 +1.5
Starter terminal B 8 × 1.25 9.8 0 1 0 7 0

Starter mounting nut 10 × 1.25 45 ±15 4.6 ± 1.5 33.2 ± 11

Glow plug (main) 10 × 1.25 25 ± 5 2.5 ± 0.5 18 ± 3.6
Glow plug (terminal) 4 × 0.7 1.3 ± 0.2 0.13 ± 0.02 0.96 ± 0.22

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 Chapter 2 SERVICE DATA

2.7 Standard bolt and nut tightening torque

2.7.1 Metric automobile screw thread
Thread Strength classification
Width across flats
Dia. × Pitch
(mm) [in.] 4T 7T 10.9
(M-thread)

4 7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 × 1.0 10 4 0.4 2.9 9 0.9 6.5 13 1.3 9.4
8 × 1.25 12 12 1.2 8.7 18 1.9 13 30 3.1 22
10 × 1.25 14 21 2.15 16 35 3.6 26 60 6.1 44
12 × 1.25 17 35 3.6 26 64 6.5 47 108 11.0 80

2.7.2 Metric course screw thread

Thread Strength classification
Width across flats
Dia. × Pitch
(mm) [in.] 7T 10.9
(M-thread)

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 32 3.3 24 58 5.9 43
12 × 1.75 17 57 5.8 42 102 10.4 75

Note:(a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are for fasteners with spring washers.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)

2.8 Standard stud tightening torque

Thread For driving in aluminum materials For driving in ferrous materials
Dia. × Pitch
(M-thread) N·m kgf·m lbf·ft N·m kgf·m lbf·ft

8 × 1.25 5.4 ± 0.5 0.55 ± 0.05 4.0 ± 0.4 12.8 ± 0.9 1.3 ± 0.1 10.1 ± 0.7
10 × 1.25 13.7 ± 1.0 1.4 ± 0.1 9.4 ± 0.7 23.5 ± 1.9 2.4 ± 0.2 17.4 ± 1.4

2-11