GSIC - Global Service Information Center

# 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.)