Ce671 08 0708
Ce671 08 0708
APPENDIX
Page 0
SST LIST ............................................................ 8-2
1
LIST OF SERVICE STANDARDS...................... 8-6
ENGINE OVERHAUL.................................................. 8-6
2
FUEL SYSTEM ......................................................... 8-10 3
COOLING SYSTEM .................................................. 8-12
LUBRICATION SYSTEM .......................................... 8-12
4
STARTING SYSTEM ................................................ 8-12 5
CHARGING SYSTEM ............................................... 8-12
6
TIGHTENING TORQUE FOR EACH PART..... 8-13
7
8
9
10
11
12
13
14
15
16
17
18
8-2
SST LIST
Section
Illustration Part No. Part name
2 3 5 6 7
09032-76001-71
Oil pan seal cutter { {
(09032-00100)
09201-76005-71
Valve stem oil seal replacer {
(09201-58010)
09201-76006-71
Remover & replacer, valve guide bush {
(09201-60011)
09202-76002-71
Valve spring compressor {
(09202-70020)
09213-76007-71
Crankshaft pulley & gear puller {
(09213-60017)
09215-76001-71
Camshaft bearing remover & replacer {
(09215-00012)
8-3
Section
Illustration Part No. Part name
2 3 5 6 7
09218-76003-71
(09218-56020)
Cylinder liner remover & replacer { 0
1
09228-76004-71
Oil filter wrench { {
2
(09228-07501)
3
09228-76010-71
4
Fuel filter wrench {
5
(09228-64010)
6
09240-32880-71 Plunger stroke measuring tool {
7
8
09245-76001-71
(09245-54010)
Injection pump arm { 9
10
09260-76003-71
Injection pump tool set {
11
(09260-54012)
12
13
09268-76003-71
Nozzle holder retaining nut wrench {
(09268-64010)
14
15
16
09286-76001-71
Injection pump spline shaft puller {
(09286-46011)
17
18
8-4
Section
Illustration Part No. Part name
2 3 5 6 7
09612-76006-71
Steering warm bearing puller {
(09612-65014)
09820-76002-71
Alternator rear bearing puller {
(09820-00021)
09820-76003-71
Alternator rear bearing replacer {
(09820-00030)
09950-76003-71
Puller C set {
(09950-50012)
8-5
Section
Illustration Part No. Part name
2 3 5 6 7
09950-76014-71
(09950-40011)
Puller B set { 0
1
09950-76018-71
Replacer set { {
2
(09950-60010)
3
09950-76019-71
4
Replacer B set {
5
(09950-60020)
6
09950-76020-71
(09950-70010)
Handle set { {
7
8
09960-76001-71
(09960-10010)
Variable pin wrench set { 9
10
09992-76001-71 Cylinder compression check gauge
{
11
(09992-00024) set
12
13
14
15
16
17
18
8-6
Cylinder head
Lower view distortion limit mm (in.) 0.15 (0.0059)
IN Distortion limit for the mounting face of the manifold mm (in.) 0.20 (0.008)
EX Distortion limit for the mounting face of the manifold mm (in.) 0.20 (0.008)
Contact width IN 1.5 to 1.9 (0.059 to 0.074)
mm (in.) EX 1.5 to 1.9 (0.059 to 0.074)
Valve seat
Contact angle
45
degrees
Valve spring
Standard 46 (1.811)
Total length mm (in.)
Limit 45.5 (1.791)
Squareness limit mm (in.) 2.0 (0.08)
Valve
IN 121.94 (4.8008)
Standard
EX 121.84 (4.7969)
Total length mm (in.)
IN 121.30 (4.7756)
Limit
EX 121.20 (4.7717)
IN 8.973 to 8.989 (0.3533 to 0.3539)
Stem outside diameter mm (in.)
EX 8.954 to 8.970 (0.3525 to 0.3531)
IN 0.021 to 0.057 (0.0008 to 0.0022)
Standard
EX 0.040 to 0.076 (0.0016 to 0.0030)
Clearance with the guide bushing mm (in.)
IN 0.10 (0.0039)
Limit
EX 0.12 (0.0047)
Limit of the wall thickness of the valve head IN 0.9 (0.035)
section mm (in.) EX 1.0 (0.039)
Contact surface angle of the valve degrees 45
Wall thickness of the valve stem cap mm (in.) Standard 1.31 to 1.49 (0.0547 to 0.0587)
Cylinder block
Upper face distortion limit mm (in.) Upper face distortion limit 0.1 (0.004)
Standard 98.00 to 98.03 (3.8583 to 3.8594)
Difference between
0.2 (0.008)
Cylinder bore mm (in.) maximum and minimum
Taper, ellipticity 0.02 (0.0008) or less
Honing allowance 0.02 (0.0008) or less
A 101.030 to 101.045 (3.97755 to 3.97815)
Cylinder liner outside diameter mm (in.)
B 101.045 to 101.060 (3.97815 to 3.97874)
Cylinder liner bottom hole diameter A 101.000 to 101.015 (3.97637 to 3.97696)
mm (in.) B 101.015 to 101.030 (3.97696 to 3.97755)
Valve lifter bottom hole inside diameter
Standard 22.200 to 22.221 (0.87401 to 0.87484)
mm (in.)
Crankshaft
Runout limit mm (in.) 0.06 (0.0024)
Standard 0.04 to 0.25 (0.0016 to 0.0100)
Thrust clearance mm (in.)
Limit 0.3 (0.012)
Standard 2.43 to 2.48 (0.0957 to 0.0976)
Thrust washer thickness mm (in.)
O/S type 0.125, 0.250 (0.00492, 0.00984)
STD 73.98 to 74.00 (2.9130 to 2.9134)
U/S 0.25 73.74 to 73.75 (2.90314 to 2.90353)
Journal outside diameter
U/S 0.50 73.49 to 73.50 (2.89330 to 2.89370)
(finishing dimension for U/S) mm (in.)
U/S 0.75 73.24 to 73.25 (2.88346 to 2.88385)
U/S 1.00 72.99 to 73.00 (2.87362 to 2.87401)
Standard 0.030 to 0.050 (0.00118 to 0.00197)
Journal oil clearance mm (in.)
Limit 0.1 (0.004)
STD 54.98 to 55.00 (2.1646 to 2.1654)
U/S 0.25 54.74 to 54.75 (2.1551 to 2.1555)
Crank pin outside diameter
U/S 0.50 54.49 to 54.50 (2.1453 to 2.1457)
(finishing dimension for U/S) mm (in.)
U/S 0.75 54.24 to 54.25 (2.1354 to 2.1358)
U/S 1.00 53.99 to 54.00 (2.1256 to 2.1260)
Ellipticity limit 0.02 (0.0008)
Journal and crank pin mm (in.)
Taper limit 0.05 (0.0020)
Engine adjustment
When installing
620 to 790 (63 to 81) [139 to 179]
V-ribbed belt tension (Reference) N (kgf) [lbf] a new one
When inspecting 405 to 555 (41 to 57) [90 to 126]
When installing
V-ribbed belt deflection amount 6 to 7.5 (0.24 to 0.30)
a new one
[press force 98.1 N (10 kgf) mm (in.)
When inspecting 8 to 9 (0.31 to 0.51)
Specific gravity of the battery (liquid temperature 20° C) 1.25 to 1.28
Coolant capacity l (US gal) Refer to repair manual for each vehicle model.
Capacity 9.4 (2.48)
Lubricating oil capacity l (US gal)
Oil pan capacity 8.7 (2.30)
Injection timing (BTDC) 0
Injection pressure kPa (kgf/cm2) [psi] 17700 ± 500 (180 ± 5) [2560 ± 71]
IN 0.20 (0.0078)
Valve clearance (warm) mm (in.)
EX 0.36 (0.0142)
Standard 3230 (33.0) [470]/260
Compression kPa (kgf/cm2) [psi]/rpm Limit 1960 (20) [280]/260
Cylinder difference 196 (2) [28]/260
Idle speed Refer to repair manual for each vehicle model.
No-load maximum speed Refer to repair manual for each vehicle model.
8-10
FUEL SYSTEM
Nozzle & Nozzle holder
Nozzle opening valve pressure
11.77 ± 0.49 (120 ± 5) [1707 ± 71]
MPa (kgf/cm2) [psi]
Injection pump
Roller ring ASSY Irregularity limit of the roller ring height mm (in.) 0.02 (0.0008)
Drive shaft Wear depth limit of the oil seal contact surface mm (in.) 0.08 (0.0031)
Cam plate Wear limit of the plunger contact surface (dimension L) mm (in.) 0.2 (0.008)
Stepped wear depth limit of the washer contact surface
Flyweight 0.2 (0.008)
(dimension A) mm (in.)
Plunger spring Squareness limit (dimension A) mm (in.) 2.0 (0.08)
Pump housing Bushing wear (looseness) limit mm (in.) 0.15 (0.0059)
0.87 to 0.93
Cam lift amount standard when inspecting the injection timing mm (in.)
(0.0343 to 0.0366)
3. Pump inner pressure adjustment (by the full position of the lever)
Pump revolving speed Pump inner pressure
Remarks
rpm kPa (kgf/cm2) [psi]
400 421 to 481 (4.3 to 4.9) [61.0 to 69.7]
Adjust with regulating valve.
1100 588 to 648 (6.0 to 6.6) [85.3 to 94.0]
4. Inspection of the overflow amount (at the full position of the lever)
Pump revolving speed
Overflow amount Remarks
rpm
1100 357 to 607 cm3/min Measure by using the overflow screw attached to
(21.79 to 37.04 cu-in/100 st.) each pump.
8-11
COOLING SYSTEM
Thermostat
Temperature when starting to open ° C (° F) 80 to 84 (176 to 183)
Temperature when fully open ° C (° F) 95 (203)
Lift amount when fully open mm (in.) 8 (0.32)
LUBRICATION SYSTEM
Oil pump
Oil pump model Trochoid system
Standard 0.10 to 0.17 (0.0039 to 0.0067)
Body clearance mm (in.)
Limit 0.2 (0.008)
Standard 0.05 to 0.15 (0.0020 to 0.0059)
Tip clearance mm (in.)
Limit 0.2 (0.008)
Standard 0.03 to 0.09 (0.0012 to 0.0035)
Side clearance mm (in.)
Limit 0.15 (0.0059)
STARTING SYSTEM
Starting motor
Motor model DC series-wound reduction model
Nominal voltage V 12
Nominal output kW 2.5
Voltage V 11
No-load characteristic Current A 90 or less
Revolving speed rpm 3500 or more
Ellipticity mm (in.) Limit 0.05 (0.0020)
Standard 36 (1.42)
Outside diameter mm (in.)
Commutator Limit 35 (1.38)
Standard 0.7 (0.028)
Mica depth mm (in.)
Limit 0.2 (0.0008)
Standard 20.5 (0.807)
Length mm (in.)
Limit 13 (0.512)
Brush
Spring mount Standard 31.4 to 39.2 (3.2 to 4.0) [7.1 to 8.8]
load N (kgf) [lbf] Limit 21.6 (2.2) [4.9]
CHARGING SYSTEM
Alternator
Nominal voltage V 12
Maximum output A 60
Output revolution speed rpm 1500
Standard 10.5 (0.413)
Brush length mm (in.)
Limit 1.5 (0.059)
Standard 14.4 (0.567)
Slip ring outside diameter mm (in.)
Limit 14.0 (0.552)
8-13