2KD-FTV ENGINE MECHANICAL > SERVICE DATA



Idle speed
700 to 800 rpm
Maximum speed
4,450 to 4,750 rpm
Compression pressure
at 250 rpm or more
2,700 kPa (27.5 kgf/cm2, 391 psi) or more
Minimum
2,200 kPa (22.5 kgf/cm2, 320 psi) or more
Difference between each cylinder
500 kPa (5.0 kgf/cm2, 71 psi) or less
Valve clearance
Intake
0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust
0.35 to 0.45 mm (0.014 to 0.018 in.)
Cylinder head set bolt
Standard outside diameter
11.8 to 12.0 mm (0.465 to 0.472 in.)
Minimum outside diameter
11.60 mm (0.457 in.)
Cylinder head gasket
New cylinder head gasket thickness
A
0.80 to 0.90 mm (0.0315 to 0.0354 in.)
B
0.85 to 0.95 mm (0.0335 to 0.0374 in.)
C
0.90 to 1.00 mm (0.0354 to 0.0394 in.)
D
0.95 to 1.05 mm (0.0374 to 0.0413 in.)
E
1.00 to 1.10 mm (0.0394 to 0.0433 in.)
Exhaust manifold
Maximum warpage
0.40 mm (0.0157 in.)
Intake manifold
Maximum warpage
0.40 mm (0.0157 in.)
Chain tensioner
Protrusion
8.1 to 8.9 mm (0.319 to 0.350 in.)
Timing gear
Gear backlash
Standard
0.02 to 0.15 mm (0.0008 to 0.0060 in.)
Maximum
0.20 mm (0.0079 in.)
Idle gear No. 1 thrust clearance
Standard
0.06 to 0.11 mm (0.0024 to 0.0043 in.)
Maximum
0.30 mm (0.0118 in.)
Idle gear No. 1 inside diameter
44.000 to 44.025 mm (1.7323 to 1.7333 in.)
Idle gear shaft diameter
43.955 to 43.990 mm (1.7305 to 1.7319 in.)
Idle gear oil clearance
Standard
0.010 to 0.070 mm (0.0004 to 0.0028 in.)
Maximum
0.20 mm (0.0079 in.)
Balance shaft thrust clearance
Standard
0.065 to 0.140 mm (0.0026 to 0.0055 in.)
Maximum
0.25 mm (0.0098 in.)
Cylinder head bolt
Cylinder head bolt outer diameter
Standard
11.8 to 12.0 mm (0.465 to 0.472 in.)
Minimum
11.6 mm (0.457 in.)
Cylinder head gasket
New cylinder head gasket thickness
A
0.80 to 0.90 mm (0.0315 to 0.0354 in.)
B
0.85 to 0.95 mm (0.0335 to 0.0374 in.)
C
0.90 to 1.00 mm (0.0354 to 0.0394 in.)
D
0.95 to 1.05 mm (0.0374 to 0.0413 in.)
E
1.00 to 1.10 mm (0.0394 to 0.0443 in.)
Cylinder head
Warpage
0.15 mm (0.0059 in.)
Valve seat (Refacing angle)
Intake
25°, 45°, 70°
Exhaust
25°, 45°, 75°
Valve seat (Contacting angle)
45°
Valve seat (Contacting width)
Intake
1.2 to 1.6 mm (0.047 to 0.063 in.)
Exhaust
1.6 to 2.0 mm (0.063 to 0.079 in.)
Valve guide bush bore diameter
Standard
10.985 to 11.006 mm (0.4325 to 0.4333 in.)
O/S 0.05
11.035 to 11.056 mm (0.4344 to 0.4353 in.)
Valve guide bush
Inside diameter
6.010 to 6.030 mm (0.2366 to 0.2374 in.)
Outside diameter for repair part
Standard
11.033 to 11.044 mm (0.4344 to 0.4110 in.)
O/S 0.05
11.083 to 11.094 mm (0.4363 to 0.4368 in.)
Valve
Valve overall length
Standard (Intake)
105.38 to 105.78 mm (4.1488 to 4.1646 in.)
Standard (Exhaust)
105.57 to 105.97 mm (4.1563 to 4.1720 in.)
Minimum (Intake)
104.88 mm (4.1291 in.)
Minimum (Exhaust)
105.07 mm (4.1366 in.)
Stem diameter
Intake
5.970 to 5.985 mm (0.2350 to 0.2356 in.)
Exhaust
5.960 to 5.975 mm (0.2346 to 0.2352 in.)
Stem oil clearance
Standard (Intake)
0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Standard (Exhaust)
0.035 to 0.070 mm (0.0014 to 0.0028 in.)
Maximum (Intake)
0.08 mm (0.0031 in.)
Maximum (Exhaust)
0.10 mm (0.0039 in.)
Margin thickness
Standard
1.1 mm (0.043 in.)
Minimum
0.6 mm (0.024 in.)
Valve spring
Deviation
Maximum
2.0 mm (0.079 in.)
Free length
Blue mark
46.8 mm (1.843 in.)
None
46.5 mm (1.831 in.)
Installed tension at 33.1 mm (1.303 in.)
Blue mark
149.9 to 166.1 N (15.3 to 16.9 kgf, 33.7 to 37.3 lbf)
None
150.2 to 165.8 N (15.3 to 16.9 kgf, 33.7 to 37.3 lbf)
Valve lifter
Cylinder head lifter bore diameter
31.000 to 31.021 mm (1.2205 to 1.2213 in.)
Lifter diameter
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Oil clearance
Standard
0.024 to 0.055 mm (0.0009 to 0.0022 in.)
Maximum
0.075 mm (0.0030 in.)
Camshaft
Circle runout
Maximum
0.03 mm (0.0012 in.)
Cam lobe height
Standard (Intake)
47.180 to 47.280 mm (1.8575 to 1.8614 in.)
Standard (Exhaust)
48.070 to 48.170 mm (1.8925 to 1.8965 in.)
Minimum (Intake)
46.76 mm (1.8409 in.)
Minimum (Exhaust)
47.92 mm (1.8866 in.)
Journal diameter
27.969 to 27.985 mm (1.1011 to 1.1018 in.)
Journal oil clearance
Standard
0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum
0.10 mm (0.0039 in.)
Thrust clearance
Standard
0.035 to 0.185 mm (0.0014 to 0.0073 in.)
Maximum
0.25 mm (0.0098 in.)
Gear backlash
Standard
0.035 to 0.145 mm (0.0014 to 0.0057 in.)
Maximum
0.189 mm (0.0074 in.)
Cylinder block
Cylinder head surface warpage
Maximum
0.10 mm (0.0039 in.)
Cylinder bore diameter
Standard (Mark 1)
92.000 to 92.010 mm (3.6220 to 3.6224 in.)
Standard (Mark 2)
92.010 to 92.020 mm (3.6224 to 3.6228 in.)
Standard (Mark 3)
92.020 to 92.030 mm (3.6228 to 3.6232 in.)
Maximum standard
92.23 mm (3.6311 in.)
O/S 0.50
92.73 mm (3.6508 in.)
Piston and piston ring
Piston diameter
Standard (Mark 1)
91.92 to 91.93 mm (3.6189 to 3.6193 in.)
Standard (Mark 2)
91.93 to 91.94 mm (3.6193 to 3.6197 in.)
Standard (Mark 3)
91.94 to 91.95 mm (3.6197 to 3.6201 in.)
O/S 0.50
92.42 to 92.45 mm (3.6386 to 3.6398 in.)
Piston oil clearance
Standard
0.070 to 0.090 mm (0.0028 to 0.0035 in.)
Maximum
0.16 mm (0.0063 in.)
Piston ring groove clearance
Standard (No. 1)
0.060 to 0.100 mm (0.0024 to 0.0039 in.)
Standard (No. 2)
0.050 to 0.095 mm (0.0020 to 0.0037 in.)
Standard (Oil)
0.030 to 0.075 mm (0.0012 to 0.0027 in.)
Maximum
0.20 mm (0.0079 in.)
Piston ring end gap
Standard (No. 1)
0.270 to 0.390 mm (0.0106 to 0.0154 in.)
Standard (No. 2)
0.470 to 0.570 mm (0.0185 to 0.0224 in.)
Standard (Oil)
0.200 to 0.400 mm (0.0079 to 0.0157 in.)
Maximum (No. 1)
1.21 mm (0.0476 in.)
Maximum (No. 2)
1.44 mm (0.0567 in.)
Maximum (Oil)
1.22 mm (0.0480 in.)
Piston protrusion from cylinder block
0.005 to 0.254 mm (0.0002 to 0.0100 in.)
Piston diameter
O/S 0.50
92.42 to 92.45 mm (3.6386 to 3.6398 in.)
Connecting rod
Thrust clearance
Standard
0.100 to 0.300 mm (0.0039 to 0.0118 in.)
Maximum
0.40 mm (0.0157 in.)
Connecting rod oil clearance
Standard
0.030 to 0.048 mm (0.0012 to 0.0019 in.)
U/S 0.25, U/S 0.50
0.037 to 0.077 mm (0.0015 to 0.0030 in.)
Maximum
0.10 mm (0.0039 in.)
Connecting rod bearing center wall thickness (Reference)
Standard Mark 2
1.486 to 1.489 mm (0.0585 to 0.0586 in.)
Standard Mark 3
1.489 to 1.492 mm (0.0586 to 0.0587 in.)
Standard Mark 4
1.492 to 1.495 mm (0.0587 to 0.0589 in.)
Standard Mark 5
1.495 to 1.498 mm (0.0589 to 0.0590 in.)
Standard Mark 6
1.498 to 1.501 mm (0.0590 to 0.0591 in.)
Rod bend
Maximum per 100 mm (3.94 in.)
0.03 mm (0.0012 in.)
Rod twist
Maximum per 100 mm (3.94 in.)
0.15 mm (0.0059 in.)
Bush inside diameter
A
34.012 to 34.016 mm (1.3390 to 1.3392 in.)
B
34.016 to 34.020 mm (1.3392 to 1.3393 in.)
C
34.020 to 34.024 mm (1.3392 to 1.3395 in.)
Piston pin diameter (Piston pin oil clearance)
Standard
0.012 to 0.024 mm (0.0005 to 0.0009 in.)
Maximum
0.03 mm (0.0012 in.)
Connecting rod bolt tension portion diameter
Standard
8.500 to 8.600 (0.3346 to 0.3385 in.)
Maximum
8.30 mm (0.3268 in.)
Crankshaft
Thrust clearance
Standard
0.040 to 0.250 mm (0.0016 to 0.0098 in.)
Maximum
0.30 mm (0.0118 in.)
Thrust washer thickness
Standard
2.430 to 2.480 mm (0.0957 to 0.0976 in.)
U/S 0.125
2.493 to 2.543 mm (0.0981 to 0.1001 in.)
U/S 0.25
2.555 to 2.605 mm (0.1006 to 0.1026 in.)
Main journal oil clearance
Standard
0.036 to 0.054 mm (0.0014 to 0.0021 in.)
U/S 0.25, U/S 0.50
0.037 to 0.077 mm (0.0015 to 0.0030 in.)
Maximum
0.10 mm (0.0039 in.)
Main journal diameter
Mark 1
69.994 to 70.000 mm (2.7556 to 2.7559 in.)
Mark 2
69.988 to 69.994 mm (2.7554 to 2.7556 in.)
Mark 3
69.982 to 69.988 mm (2.7551 to 2.7554 in.)
Main bearing center wall thickness (Reference)
Standard Mark 2
2.482 to 2.485 mm (0.0977 to 0.0978 in.)
Standard Mark 3
2.485 to 2.488 mm (0.0978 to 0.0980 in.)
Standard Mark 4
2.488 to 2.491 mm (0.0980 to 0.0981 in.)
Standard Mark 5
2.491 to 2.494 mm (0.0981 to 0.0982 in.)
Standard Mark 6
2.494 to 2.497 mm (0.0982 to 0.0983 in.)
Crank pin diameter
Mark 1
58.994 to 59.000 mm (2.3225 to 2.3228 in.)
Mark 2
58.988 to 59.994 mm (2.3223 to 2.3225 in.)
Mark 3
58.982 to 58.988 mm (2.3221 to 2.3223 in.)
Circle runout
Maximum
0.06 mm (0.0024 in.)
Main journal taper and out-of-round
Maximum
0.02 mm (0.0008 in.)
Crank pin taper and out-of-round
Maximum
0.02 mm (0.0008 in.)
Main bearing cap bolt outer diameter
Standard
13.500 to 14.000 mm (0.5315 to 0.5512 in.)
Maximum
12.60 mm (0.4961 in.)