fas — fii! — fe AA SERVICE SPECIFICATIONS Page ENGINE MECHANICAL Az FUEL SYSTEM . AT COOLING SYSTEM A-20 LUBRICATION SYSTEM 2 ART STARTING SYSTEM ee ABZ CHARGING SYSTEM 2 ABA SERVICE SPECIFICATIONS — Engine Mechanical ENGINE MECHANICAL Specifications “Engine tune-up | Engine cootent capacity (wi Heater 8820, 22, 30 15.0 liters 1SSUSats «13.2 Imp. ats 860 133iiers 141 US ais 11.7 imp. gts 870, 71, 73, 74,75, 38 128 iters 146 US ats 12.1 imp. ats 138-7 MIT | 142 mers 180USats 12 5 imp. ais 138-7 AT 136 lites 144US ais 12.0 mp. ais. BUEO, 61, 62, 63, 68, 70, 75, 76, 80, 81, 82, 85, 86 |" Reguier est 12S ites 132 USats 11.0 Imp.ats Wide cab 1BO liters 1837S ats 11.4 Imp. ats Bya3, 42 122iters —«128US gts 10.7 Imp. gre Engine et eapacity Drain and refill vwio Oil fier change SBiters 6.1 US ats 5.1 Imp. gts wf Oil fiter change B7iters 7.4 US ats 5.9 Imp. ats Dry fil 7aies 7.7 US ate 6a imp. ats Battery specific gravity 1.25 = 1.27 when fully charged at 20°C (68°F) Drive bett Tension (Canedal Now belt 145 = 251 Used bet 100 + 201 Deflection (Others) Single belt New bait B= 12mm 0.31 = 0.47 in, Used belt 1b = 16 mm 0.83 ~ 0.83 in ‘Double bett New belt 12-15 mm 0.87 - 0.59 in Used belt 14 = 20 mm 0.85 ~ 0.79 in. Tension Reterencel Single belt New belt 55 - 88ko Used belt 30 ~ 45 kg Doubie belt New belt 45 - 58k Used belt 20-358 kg Injection nozzle opening pressure . 8 ond 3B New nozzle 115 — 125 kglem? (1,836 = 1,778 psi, 11,278 = 12.258 kPa) | Reeused nozzle 108 — 125 kg/e | (1,493 — 1,778 psi, 10.296 - 12.258 KPa) | 198, 198 ena 138.7 New nozzle 200 ~ 210 kg/em* j (2.845 ~ 2,987 psi, 19.613 - 20,594 KPa) Revsed nozzle 180 ~ 210 kg’em* (2,560 ~ 2.987 psi, 17.652 ~ 20,584 4Pal Valve cleerance Hot) = 0.20 mm 0.008 in ex 0.36 mm 0.014 in Injection timing. | B ond 38 | 14 stoc 1B (w/ HAC) and 138 (w/ HAC) | 1a" BTDC 118 tw/o HAC) anc 138 bw/o HAC) 11 BTDC. 138.7 : 11" TDC. Injection order 13-42 Idle speed MT 650 rm ACT (1381 770 rpm AT 038-71 820 rpm Moximum speed 4,100 rom AIC iaie-up setting speed 750 rpm 880 mam' SERVICE SPECIFICATIONS — Engine Mechanical Specifications (Cont'd) AS ‘Compression pressure Engine revelution at 250 rpm std Lim Difference of pressure between each cylinder 30.0 kgiem: (427 psi. 2.942 Pal oF more 200kglem? 284 psi 1.961 KPa 2.0 kg/em? (28 psi, 196 kPal or less Turbocharger ‘Cylinder Turbocharging pressure lrnpeller wheel axial play | Cylinder block side warpage 16.0 ~ 8.0 psi, 41 — 55 kPal 118, 138, 138-7 Squareness Lit 020 mm 0.0079 in Manifold side warpage Limit 0.20 mm 0.0079 in Valve seat Refacing enale 30°, a5", 60" Contecting angle 45° Contacting width 19-23mm 0.075 - 0.091 in. Valve guide Inner diameter 9,010 = 9.030 mm 0.3547 - 0.9555 busing Outer diameter 14.023 - 14.041 mm 0.5521 - 05528 Vaive Vaive overal length sto 127.95 mm 5.0374 in eX 8.38 127.75 mm 5.0295 in, 198, 138, 138-7] 127.95 mm 5.0374 in Limit IN 127.45 mm 5.0177 EX 8.38 127.25 mm 5.0098 118, 138, 138-T| 127.45 mm 6.0177 in. Valve face angie 255° Stem diameter N 8.968 - 8.984 mm 0.3531 = 0.3537 in. EX 8, 48,118,138 | 8.954-8.970mm 0.3525 ~ 0.3531 in. 138-T 8.940 = 8.956 mm 0.3520 - 0.3526 in. ‘Stem oil clearance STD IN 0.026 ~ 0.062 mm 0.0010 - 0.0024 in, EX 8, 98,118, 138 | 0.040 - 0.076 mm 0.0016 = 9.0030 in, 138-T 0,054 - 0,090 mm — 0.0021 ~ 0.0035 in. Limit IN 0.10 mm 0.0039 in. eX 8,38, 118,138 | 0.12 mm 0.0047 in 138-1 013mm 0.0051 in. Margin thickness STD IN 1mm 0.055 in, x 8,38 1.8mm 071 in 118 13mm 9051 in 138, 138-1 17 mm 0.087 in Lienit IN 0.9 mm 0.038 in, ex 8.38 13mm 0.051 in. 118 08 mm 0.031 in. 138,19-7 | tamm 0.087 in Venesprng | Feelngth STD Inner 6. 38 4550 mm 1.7913 in 118, 138, 138-1] 5484mm 23591 in outer 8, 38 4752 mm 418708 in ‘ 118, 198, 138-7) 58.30 mm 2.2988 in Installed tension inner 8. 38 5.95 kg (13.1 Io, 58 N) 2138.05 mm (1.4499 16) 178, 198, 138-1) 14.2 kg (31.3 tb, 139 Nb a1 42.25 men (1.8534 in) Outer 8, 38 25.53 kg (56.3 tb, 250 NI ‘91 39.55 mm (1.5571 in} 27.8 kg (61.2 Ib, 273 NI at 44,75 mm (1.7618 io? 2.0 mm 0079 inAA SEAVICE SPECIFICATIONS — Engine Mechanical Specifications (Cont'd) Cam lobe height STD WN Limit IN Journal diameter No.1 No.2 No.3 No.4 No. 5 Bearing inside diameter Nod No. 2 No.3 No. 4 No. 5 Journal oil clearance Thrust clearance 8.368 118, 138 138-7 8.38 118, 138, 138-7 8.38 118, 138 138-T 838 118, 138, 198-7 st Lien STO Limit 45.067 = 45.187 mm 44.708 ~ 44.795 mm 44,909 ~ 44.999 mm 45.065 ~ 45.155 mm 44.774 ~ 44.864 rum 44.63 mm 44.27 mm 44.47 mm 44.63 mm 44.34 mm 89.459 - 53.475 mm 53.209 ~ $3225 mm 52,959 - 52.975 mm 52.709 = $2725 mm 52.459 = $2475 mm 53.495 - 53.588 mm 53.245 ~ 53.318 mm 52.995 - §3.068 mm 52.745 = 52.818 mm 52.495 - 52.563 mm 0.020 ~ 0.108 mm 0.15:mm 0.06 - 0.13 mm 0.30 mm Hocker arm | Rockor arm inside diame 1as12 - 18533 mm 07288 ~ 07286 and shaft Rocker shaft dismeter 18.472 = 18.493 mm 0.7272 = 0728) in Racker arm to shaft oll clearance sto 0019-0061 mm 0.0007 - 0.0028 1, Lint 9.10 mm 0.0039 in Push rod. Circle runout 050mm 0.0197 in, Tniake and | Manifold surface wernage exhaust eit 0:20 mm 0.0078 in manifoid ‘Combustion Protrusion Minus 0.05 — Minys 0.0020 ~ ‘chamber Plus 0.05 mmm Plus 0.0026 in B38) - Camshaft | Circle runout Limit 2.08 mm 0.0028 in 1.7743 ~ 1.7748 in 1,7600 — 1.7696 in, 1.7681 ~ 1.7716 in. 1.7742 — 1.7778. 1.7628 — 1.7662 in, 1.7871 in 1.7429 in, 1,7508 in, 1.7571 in, 1.7457 in, 2.1087 = 2.1053 in 2.0948 ~ 2.0855 in 2,0850 — 2.0856 in. 2.0782 — 2.0758 in. 2.0853 — 2.0659 in 2.1061 = 2.1080 in| 2.0863 — 2,0991 in| 2.0864 = 2.0893 in. 2.0766 ~ 2.0794 in. 2.0867 ~ 2.0696 in. 0.0008 = 0.0043 in. 0.0059 0.9024 - 0.0051 in. 0.0118 in Timing geer™ ‘Gear backlash leach gear) Ile gear thrust clesrance Idle gear shoft diameter Idle gear inzide diameter Idle gear ol clearance STO Limit sto Lienit sto Limit 0.058 - 0.162 mm 0.30. mm 0.08 - 0.17 mm 0.30 mm 44,995 — 44.955 mm 44.969 = 44.935 mm 0.014 - 0.960 mm 0.15 mm (0.0023 = 0.084 in 0.0118 in 0.0024 = 0.0067 in. 0.0118 in, 1.7691 ~ 1.7699 in 1.7704 ~ 4.7715 in. 0.0006 - 0.0024 in 0.0058 in, ‘Valve titer Valve liter digmeter Vatve lifter bare diam Oil clearance s1D Limit 26.972 — 26.985 mm 27.010 — 27.030 mm 0.025 - 0065 mm 0.10 mm 1.0619 = 1.0624 in 1.0624 - 1.0642 19 0.0010 = 00026 in 0.0039 inSERVICE SPECIFICATIONS — Engine Mechanic) Specifications (Cont'd) = [evtinder black and cylinder Cylinder head surface warpage Limit 0.20 mm 0.0079 in Cylinder bore diameter sto 8.178 9500-9509 mm 3.7402 - 3.7419 in, Bu'1g8, 198-7 | 102.00-- 10203 mm 40187 — 40189 Limit 8,118 95.23 mm 3.7482 38, 138, 138-T | 102.23 mm 4.0288 in. Cylinder tiner ridge protrusion or o10mm —_ 9.0004 ~ 0.0038 in Piswonand | Piston ciameter 8 3490-9893 mm 97362 - 3.1974 in piston ring 28 $br90 — 101,93 mm 4.0118 ~ 40130in. 148 gag 9497 mm 3.7378 ~ 3.7380 in 138 191.93 — 101.98 mm 4.0130 ~ 40142 in, 438-7 10182 — 101.95 mm 4.0126 ~ 4.0138 in Piston oil elearance sto 8,38 09 0.11 mm 0.0085 ~ 0.0043 in vB os - 007mm «0.0020 - 0.0028 138 206 -0.08mm 9.0024 ~ 0.0031 in 138-7 907 0.03 mm 0.0028 — 0.0035 i. eit 0.15 mm 10,0059 in. Piston ring groove clearance No.1 178,138 oa = 0.12 mm 2.0031 ~ 0.0047 in. No.2 638,118,198 | 0.04 — 0.08 mm 0.0016 ~ 0.0031 in, 138-1 906 0.10 mm 0.0024 ~ 0.0039 in, ol Bos 0.07 mm 0.0012 ~ 0.9028 in Piston ring end gap STD Nod 8 935 -064mm 9.0138 ~ 0.0282 in. 38, 118, 128, 198-T| 0.30 - 0.54 mm 9.0118 - 0.0213 in. No.2 8,118 038 —064mm —«.0138 ~ 0.0252 in. Boge 1a8-T | 0s— 068mm —— O01 0.0272 in on 8.18 O25 0.68 mm 0.0138 - 0.0252 in 3a 138, 138-7 | 0.40 - 0.69 mm 0.0157 - 0.0272 in, Limit No 8 14d mm 0.0567 in. 38, 118, 196, 138-7) 1.34 mm 0.0528 in i No.2 8,118 1.44 rom 0.0867 in 38,138, 198-7 | 1.43 mm 0.0887 in. or «8.198 1.44 mm 0.0867 in. 3a, 138,138-T | 149mm 0.0587 in. Connecting rod | Thrust clearance STD 9200-0320 mm 0.0079 - 0.0126 in. Limit | 0.40 mm 9.0187 in | punning inside lamer 8 39.009 = 29.019 mm 1.1421 - 1.1426 in \ 38 132.009 - 92.019 mm 1.2002 - 12608 in i $54 yg, 13et | 34.009 - 34.019 mm 13989 © 1.3393 in. | piston pin diameter B | 39000 — 29.010 mm 1.1417 - 11421 in \ 38 | 32.000 — 32.010 mm 1.2598 = 1.2602 in \ 38, yan, 138t | 34.000 - 34.010 em 19368 — | 3990 in. | Piston pin oil clearance 008 — 0.014 mm 0.0002 ~ 0.0008 in 0.05 mm 2.0020 in. | Bena amit per 100 mm (3.94 in) | 0.08 mm 0.0020 in Ts tina par 100 ram (3.94 iad _| 0.08 rhe 0.0020 in.AG SERVICE SPECIFICATIONS — Engine Mechanical Specifications (Cont'd) Crankshaft Thrust clearance STD Limit Thrust washer thickness STD size o/s 0.125 01S 0.250 Main journal diameter STO size us 0.28 u/s 0.50 u/s 1.00 Moin journal ail clearance $10 Limit ‘Main bearing thickness at center wat STO size Yetlow STD size Green Crank pin diameter 8 STO size Ws 025 u/s 050 uss 1.00 38, 178, 138, 138-7 STD tise US 0.25. US 0.50 Urs 1.00 Crank pin oil clearance = STD Lien ‘Crank pin (connecting radh bearing thickness at center wal STO sive Brown of Yetiow STD size Black o Green Circle runout Limit Taper and out-of round Main journal and crank pin Limit 0.040 = 0.250 min 0.40 mm 2.430 ~ 2.480 mm 2.493 = 2543 mm 2.855 - 2.605 mm 69.93 ~ 70.00 mm 63.76 = 68.75 mm 69.49 ~ 69,50 mm 68.99 ~ 69.00 mm 9.080 - 0.074 mm 0.15 mm 2.480 ~ 2.485 mm 2.485 = 2.490 mm 58.98 ~ 58.00 mm 58.74 - 58.75 mm 56.48 ~ 58.50 mm 87.99 - 58.00 mm 60.88 = 61.00 mm 60.74 ~ 60.75 mm 60.49 = 60.50 rim 89.99 ~ 60.00 mm 0.030 - 0.070 mm 0.10 mm 1.680 ~ 1.485 mm 1.485 = 1.490 mm 0.08 mm 0.02 mm 0.0016 = ooosa n, 0.0187 in, 0.0857 = 0.0976 in, 0.0881 ~ 0.1001 in 0.1008 - 0.1026 in 2.7551 = 2.7589 in 2.7487 - 27461 in 2.7358 = 2.7362 in 2.7161 ~ 2.7165 in 0.0012 ~ 0.0028 in. 0.6059 in, 0.0876 — 0.0978 in, 0.0878 — 0.0920 in 2.3220 — 2.3228 in. 2.3126 = 23130 in, 2.3028 ~ 23031 in. 2.2831 - 2.2835 in. 2.4008 ~ 2.4016 in, 2.3913 = 2.3917 2.3815 = 23819 2.3818 ~ 2.2622 in. 0.0012 = 0.0028 in, 0.0039 in, 0.0583 — 0.0585 in, 9.0585 ~ 00587 in, 0.0031 in 0.0008 in,SERVICE SPECIFICATIONS — Engine Mechanical, Fuel System Torque Specifications AT Pon ighiened Tkeem = Nm Turbine outlet elbow x Turbocharger (138-7) | 375 27 37 | |_| Turbocharger x Exhaust manifold (138-7) | 465 34 46 "> | water by-pass pipe x Turbocharger 15 85 int 7 Turbocharger oil pipe x Cylinder black Unit bolt | 130 9 13 Bott 185 13 18 Turbochargt 6 pipo x Turbocharger | ass 8 8 Cylinder head x Cylinder block | 1,200 a7 118 } | Valve rocker support x Cylinder head | 38 13 18 _ | Cyinger hese eaver x Cylinder head 125, 8 12 Exhaust merifotd x Cylinder head | 475 3 7 Woter outlet houting x Cylinder head 185 13 18 Intake manifold x Cylinder head | 185 3 18 | Glow ptug x Cylinder head (8, 38) | 128 9 12 | Gamshatt timing gear x Camshatt 375 27 37 | | Camshatt thrust plate x Cylinder block 185 13 18 1 | tate gear x Cylinder block 475 34 ar lee gear shaft union bott | 110 a u ‘Timing gear cover x Cylinder block 12m belt head 185 13 18 14 mm bolt hesd 375 a 37 Crankshett pulley x Crankshaft 2.850 a7 240 1 | Push red cover x Cylinder block 185 13 18 |_| Main bearing cap x Cylinder block 2,000 145 198 Connecting rod cap x Connecting rod B 750 54 74 J 38, 118, 138, 138-T 1,200 87 8 | | Rear cit seal retainer x Cylinder block igs 13 18 B= | Flywneo! x Crankshaft 1/7) 1,800 130 7 Drive plate x Crankshaft (AT) 1,200 87 118 FUEL SYSTEM Specifications Inject nozzle Nozsle vee 8 NO-bn ¢ 80 24 ND 80 38 ND-DN 4 SDND 135 Nozzle opening pressure See page A-2 Pressure adjusting shim thickness 00 mm 0.0398 in, 1 1.05 mm 0.0413 in 3.10 men 0.0433 in. 4.35 mm 0.0453 in, | 120mm 00472 in 1.25 mm 0.0492 in. fb 1,30 mm 0.0812 | 1.35 mm 0.0831 H 1.40 mm 0.0881 1.45 mem 0.0871 in. ‘ 1.80 mm 0.0591 in. 1.55 mm 0.0810 in 1.80 mm 0.0830 in 1.85 mm 0.0850 in. 1.70 mm 0.0868 in. 1.75 mm 0.0689 in 5 1.80 mm 0.0308 in 1.85 mm 0.0728 in. 1 1.80 mm 0.0788 in. 1.95 mm 0.0788 in.ce SERVICE SPECIFICATIONS — Fuel System FUEL SYSTEM Specifications injection nozzle | Nozzle type ne NO-DLLA 1S5P 18 11B, 136, 138 ND-DLLA 150P 9 ver | 138-7 ND-DLLA 150P 10 Nozzle opening pressure See page A-2 Pressure adjusting shim thickness 0.700 mm 0.0276 in 0.750 mm 0.0295 in | 0.800 mm 0.0318 in | 0.850 mm 0.0335 | 0.900 mm 0.0356 in | 0.950 mm 0.0376 in | 0975 mm 0.0384 in. 1.000 mm 0.0384 in. 1.025 mm 0.0408 in 1.050 mm. 0.0413 ia 3.078 mm 0.0423 in 1.100 mm 0.0433 in 1.125 mom 0.0443 in 1.180 mm 0.0453 in. 4.475 mm 0.0463 in, | 1.200 mm 9.0472 in, 1.225 mm 0.0482 in. | 1.250 mm 0.0492 in, 1.275 mm 0.0502 in 1.300 mm 0.0512 in. 1,325 mm 0.9522 1350 mm 0.0531 1.375 mm 0.0541 1.400 mm. 0.0551 in. | 1.425 mm 0.0561 in. | 1.450 mm 0.0571 in 1475 een 0.0581 in i 4.500 mm 0.0581 in . | 1.850 mm 0.0619 in. | 1.600 mm. 0.0630 in 1.650 mm 0.0850 in, ; 1,700 rom 0.0869 in | 1.750 mm 0.0883 in i 1.800 mm 0.0709 in Feed pump —_| ‘Svetion test } | Suction pipe Inner dismeter | & mm. 0.31 in, | length 2m 78.7 in | Sostan bean | tm 232m Priming pure ‘at 60 stroke/ min.| Fuel must discharge within 25 strokes Feed pump at 150 cpm Fuel must discharge within £0 seconds | oer Pressure at 600 rpm 1.8 ~ 22 ko/em? s | 26 - 31 psi, 177 = 216 kPa) Discharge nozzle diameter 1.54 mm 0.0608 in Volume at 1,000 rpm 900 ccimin, (54.9 cw in. min) oF moret SEAVICE SPECIFICATIONS — Fuel System Specifications (Cont'd) [ratematc | Timer spring free tength mer 8 tener 437 mm 1.7200, ‘cuter 582 mm 2134 in 38 50.7 mim 1.996 in 118 (wie HAC), 198 (wre HAC) 50.3 mm 1.980 in 118 bw! HAC). 138 fw! HAG) 244 mm 1.748 in 138-7 485 mm 1.909 in. Timer advance angie 8 at700 pm | 0.5" or less a750rm | 03-13" a 900 ram | 27-37" at1.100mm | 35—45° at 1/400 pm | 48 —5.8° at 1,750 mpm | 6.0 = 7.0" L 881.850 1pm | 60 ~ 7.0" | 38 at 700mm | 0.5 or less atgoormm | 02-1.1° L at 1,000 pm | 1.3 - 23° | at 1.400 pm | 38-48" at 1.750 pm | 60-70 L 3 1/800.pm | 60 -7.0° I 118 fw/o HAC) at 1450cpm | 0.8% or less ati750pm | 45-55° 138 (w/e HAC) at 1.400 mm | 05° or less 7} at t700 rpm | 5-55" 118 bw! HAC), 198 (w/ HAC) ' 1,000 rom | 0.5* or less a at 1,700 pm | 3.0- 40° 198-7 at 11800 rm | 0.5" or less at 1.700 rpm | 35-45° — ‘Timer adjusting shim thickness 8, 38 O.1 mm 0.008 in, 0.2 mm 0.008 in. 05 mm 0.020 in. c * 148, 138, 138-T O5 mm 0.020 in. i 0.6 mm 0.024 in. 0.7mm 0.028 in. o38mm 0.031 in, 03mm 0,035 in. 1.0 mm 0.039 in.A-10 SERVICE SPECIFICATIONS — Fuel System Specifications (Cont'd) Injeetion pump ae Direetion of rotation Camshaft thrust elesrance STO Limit Camshaft thrust washer thickness. Control rack siding resistance Delivery valve spring free length Plunger spring free length Governor main spring free length B 38 Speed control spring free fength HAC push rod stroke fw/ HAC) HAC push rod clearance (w/ MAC) at sea level ‘Clockvice as seen from drive side 0.03 - 0.05 mm. 0.0012 ~ 0.0020 in, Ot mm 0.008 in 0.10 mm 10,0039 in 0.12 mm 0.0087 in 0.14 mm 0.0055 in. 0.18 mm 0.0083 in 0.18 mm ooo7t 0.50 mm 0.0197 in, 120 g (6.2 o7) or less 37.0 mm 1.457 in, 49.2 mm 1.945 in 45.6 mm 1.795 in 51.6 mm 2031 in, 38.0 mm 1.496 in, 31 -38mm 0.122 - 0.142 in. 0.1 - 0.3 mm 0.904 - 0.012 in, Tnjgetion pump (118. 198.) 138-7 Direction of rotation ull stop cam thrust elearance Full stop cam thrust washer thickness ‘Steering lever thrust clearance ‘Steering lever thrust washer thickness Cam plate thrust clearance Cam piste thrust washer thickness Floating arm thrust clearance Floating aren thrust washer thickness, Jointing bolt thrust clearance Sliding weight shaft fitting dimensions Sliding weight shatt length Flyweight thrust elesrance (MT) Flyweight thrust washer thickness (M!T) Clockwise ag seen from drive side 0.03 = 0.08 mm 0.0012 ~ 0.0032 in. 0.05 mm 0.0020 0.10 mm 0.0038, 0.20 mm 0.0079 in, 0.05 - 0:20 mm 0.0020 ~ 0.0079 in, 0.50 mm 0.0187 0.55 mm 0.0217 0.60 men 0.0236 in. 0.85 mm 0.0256 in 0.70 mm 0.0276 in 0.75 mum 0.0295 in 0.80 mm 0.0315 0.08 ~ 0.12 mm 0.0031 ~ 0.0047 in. 0.2 mm 0.008 0.3 mm 0.012 in 0.4 mm oor 0.5 mm 0.020 in 0.05 - 0.12. mm 0.0020 ~ 0.0047 in. 0.05 mm 0.0020 in, 0.10 mm 0.0039 in 9.20 mm 0.0079 in, 0.40 mm 0.0157 in 1.5 - 20mm 0.059 ~ 0.079 in. 49.7 = 50.1 mm 1.987 = 1.972 in 30.7 mm 30.8 mm 31.1 mm. 31.3mm 1.232 in 31.5 mm 1.240 in, 31.7 mm 1.248 in. 21.9 me 1.286 in, 0.02 = 010 mm 0.0008 = 0.0039 in 1.80 mm 0.0830 in, 1.65 mm 0.0880 in 1.70 mm 0.0870 in 1.75 mm 0.0689 in, 1.80 mm 0.0708 in. SRE RE a6i SERVICE SPECIFICATIONS — Fuel System Alt ee Specifications (Cont'd) j= Pinjection pump | Fiyweight thrust washer thickness {cont’ch 1.85 mm 9.0728 in, (18 138 1.99 mm oo7ae 1 | canvas 195 mm 9.0768 in i 200 mm 9.0787 ia 210 mm 90827 in 220 mm 0.0866 in, \ 2.30 rm 0.0806 in. ic Stopper arm thrust clearance 0.05 = 020 mm 0.0026 - 0.0079 in Stopper atm thrust washer thickness 0.1 mm 0.2 mm | 0.5 mm Camshaft thrust clearance sto 0.03 - 9.05 mm 0.0012 ~ 0.0020 in 7 Limit O1 mm 0.004 in, a Camshaft thrust washer thickness. Front 0.10 mm 0.0039 in. 0.12 mm 0.0047 in ; 0.14 mm 0.0088 in. 0.16 mm 0.0063 in. Ip 018mm 0.0071 i. 050mm 0.0187 in : Rear 0.10 mm 0.0039 in, I 0.15 mm 00088 in, 0.30 mm 0.0118 in 0.50 mm 0.0197 in, \ Control rack sliding resistance 120 g {4.2 or) or less Delivery valve spring free length 138mm 0.789 i. A Plunger spring free length 49.4 mm 1.945 in | Mechanical gavernor spring free length 102 mm 0.402 in. a Speed control spring free length 246.0 mm 0.945 in, Inner idle spring free length wt 26.0 mim 1.024 in, 1 AT 24.4 mm 0.961 in = Outer ile spring free tength 23.8 mm 0.997 in. HAC push rod stroke wv! HAC) 3.1 - 2.6 mm 0.122 = 0.142 in HAG push rod clearance (w/ HAC) at sea level | 0.2 ~ 05 mm 0.008 ~ 0.020 in _ Q Boost compensator push rod stroke (138-Tl | 4.0 - 5.0 mm 0.187 - 0.197 in Boost compensator pressure drop (138-7) | 10 seconds or more Fullioad stopper pre-setting Stop cam to stopper housing distance r 11B (w/o HAC), 138 (w/o HAC) 27.0 mm 1,083 in 118 Ww) HAC), 138 bw/ HAC), 138.T | 22.5 mm 0.296 inSERVICE SPECIFICATIONS Injection Pump Adjustment (Pump Body) Fuel System Preparations of pump tester Test noztle type = B 38 118, 138, 138-T | ‘Test nozzle opening pressure 338 | (636 — 1,778 psi 19,278 - 12,258 xa) 11, 138, 138-7 170 ~ 180 xgiem! (2.418 ~ 2.560 psi 18,671 - 17.651 Kal Injection Outer ciameter 60 mm 0.236 in, Inner diameter 2.0mm 0.073 in. Length 600 mm 23.62 in, Minimum bending radivs | 25 mm (0.98 in) ar more Fuel temperature 40 - 45c 108 = 113" Fuel feeding pressure 8, 38 05 kg/cm? 7.1 psi 49 KPa 118, 138,138-T | 20 kg/cm? | 28 psi 196 kPa DN 4 SD 24 ND 80 DN 4 SOND 135 DN 12 SD 128 115 = 425 kg/em® Control Rack Sliding resistance Pump at 0 rpm Pump at 1,000 rpm 120 9 (4.2 o2) or tess 50 g (1.8 o7! or less Injecting timing Pre-svoke 38 8, 138, 138-7 Injection intervat Teppet clearance 1.90 - 200 mm 3.05 = 3.15 mm 89°30" - 80°30" 0.2 mm (0.008 in} or more 0.0748 — 0.0787 in, 0.1201 — 0.1240 in, Adjusting shim thickness 0.10 mm ‘0.0038 O15 mm 0.0053 0.20 mm 9.0078 030 mm ore 40 mm 0.0158 in 050 mm 0.0197 in 0:60 mm, 0.0236 0.70 mm 0.0276 in 0.80 mm 0.0315 0:80 mm 0.0356 1.00 mem 0.0394 in, 1.10 mm 0.0233 in 7 4.20 mum 0.0472 in 1130 mm 0.0819 ia, 1.40 mm 0.0581 in Tancton volume Tack position | Meazuring | jection volume | Variation limit : tem | Pack ponte | Pump om| Mena ‘ce feu in} cc leu inl 160 140 - 160 (830 00 |__ 200 | was-ose) | 12 O07 86 45-56 (o33e)_| 1.090 300 | 25-034 | 04 02 117 10.0 = 106 8 foasoy | 1-100 200° | osr- 06s) | 24 002) 117 TOA 114 (oaeo)_| 1.700 200 | os3—o70) | 28 04 65 25-45 (0256) 328: 500 | ors - 034) | 1.0 10.06)SERVICE SPECIFICATIONS — Fuel System jection Pump Adjustment (Pump Body) (Cont'd) ANB Tection volume nem | BEER [rum rom | Negte™® | SSeS lag as [wo | 200 | gae- ibn] teen 28 oot | 1000 | 200 | oie-aan| 8 004 oe ey | vsco [ae oa on [28 woe) 22100-58022 | i309) 1,700 200 ioe a7a | 09 008) ose) $250 | 500 ee 83, | 15 0.09 aby | 100 200 ees 388) L 1210071 ois | 100 | 200 | pie-6in| ceon fond 0308) 1,100 200 bub = ohn | 94 0.0m 2a, , w700 | 200 | ges-ori| 06004 L pits 325 | $00 ie ose | 1010.08) ee | 1 | 200 | agr-oam| ser | 418 2s) | 1100 | 200 | daz-aro | 99 'on Wienect 002) 1,800 200 oad 83h | 12 @0n ween |__| 500 | gxizsta | 100m (0.8301 190 200 39 = 342, | 1.8 0.100 118 eas) | taoo | 200 | wxe-aga | 9908 wivacl [~398, | 1800 | 200 | ioxr-ooa | 12007) ares, | 225 | $00 | ht zoen| 18008) sso yo | 700 | pre-e} Teor 138 MIT, 1 T 108 - 12.0 | wonme | 103, | 300 | ano | 887872 | azicon aay | 275 | 89 | ost =os | 100% wrinc) [304] 1700 | 200 | pugzoan| 1200” sires, | ss | 00 | oxizeso| 180m a8Ads SERVICE SPECIFICATIONS — Fuel System Injection Pump Adjustment (Pump Body) (Cont‘d) 7—_— injection volurne Rack positon Meaturing | Injection volume | Verlotion Tima Con fem | ram fin) [Puma som] stroke | ee teu int ce (ev ny 160 788 - 228 (0.630) 100 200: O15 = 1.39) 1.6 40.10) 102 ii2=118 | (0.402) 41106 200 (aga 0.72) | 99 (0.05) Hea 100 | 106-118 = | 28) | a200 200 (oes 07m) | 1210.07) aa] | 425-725 | wasn | 490 2 (926-044) | 15 (0.08) ieee 100 200 a8 = 158) | 2.61010) 4 135-143) teaan | 1.100 200 (oss oan | 0.9 (0.05) ee 108 129-138 (0.429) 700 200. 079-085) | 12 (0.071 “ApprOX. 35-85 o8%e | as | _s00 | gif 8iy | 19000 1 = a 10.8 128 = 136 agar toa) | 1.100 200 7808s | 29 (0.08) esi | 1700 | 200 | 688-053, | 12 007 mas 400 500 638 22a | 1.5 10.09) Injection Pump Adjustment (Governor B and 3B) ‘Vacuum chamber] Pressure drop [10 seconds or more Vacuum Rack position bees Purp rem | men HO fin. HO, kPa} mm din} . 600 (23.62, 5.88) 117 (0.861) 8 600 649 (25.20,6.28) | 114-117 (0.449 - 0461) 750 12953,7.35) | 93-107 (0966 - 0420) cota at 400 (15.75, 3.92) | 127-137 (0500-0561) old weather | ee) soo | 580 12283, 568) | 129-192 ABs - 0820) Ne Bisons 760 12756, 6.86) 87 = 107 0.383 — 0.421) 400 (15.75,382) | 128 (0508) a 600 $80 (2283, 5.68) | 125-129 0402 — 0508) (Others! 700 (27.56,6.86) | 89-105 (0350-0415) ‘Adjusting shim thickness 05 mm 0020 in 1.0 mm 0039 in 20 mm 0078 in 3.0 ren 0.118 in Idle spring Vacuum Control rack position aaa Pomp rp | mmm H.O lin. H,0. KPa) mm (in) 850 (9346.834) | 75-85 (0205 — 0335) 8 600 950 (37.40, 932) 71 = 73 (0280-0287) asm mt ag ay =SEAVICE SPECIFICATIONS — Fuel Systom AAS Injection Pump Adjustment (Governor B and 38) (Cont'd) Tae seta Vacuum Ccanvelresk positon (conta ae Pump re sum H,0 lin. HO. Pak __ en in) a (comes) ca 1,000 (39.37. 9.81) 6.7 ~ 7.3 0.264 ~ 0287) wart Te wae rim | 89-84 0187 - 0252 38 aes. 7,000 9.37, 981) a2 71 0272 - 0260) LL (Others) [200 4724, 18.77) 32 = 62 (0208 - 0244) | Segeg ene a ies Specifications Engine oil capacity | 03 kpleen® 4.2 psi, 29 KPab or more 25 = 60 kg/cm? (a6 — 85 psi, 245 - 888 KPa) 9ag0-0.180mm 9.0035 ~ 0.0059 in. (ll pressure abide at 3,000 em Sapme | Sew boay dewance STO Gear tip clearance | “Driven gear to eresent STD 0383-0476 mm 0.0155 — 0.0187 in. \ Limi 055 mm 00217 in | Drive gear to cresent sTO 0.477 = 0.567 mm 0.0188 ~ 0.0253 in | Lienit 0.85 mm 0.0256 in. rive spline to rotor backlash STD Ogd1 TO7aO mm —-0.0213 — GOFTT in Limit 1.00 mm 0.0394 in DaPump | Retor body clearence STO 0.148 —0.220mm = 9.0057 ~ (0.0087 in. (ue) | Lin 0.40 mm 0.0157 in 136-T ©! | Rotor side clearance TD 0038 G,.090mm 0.0014 ~ 0.0035 in Lien 0.45 mn 0.0089 in ‘Rotor tip clearance sTo 0110 - 0.240 mm 0.0043 — 0.0004 in Lieit 0.30 mm 0.0118 in. Drive spline to rotor backlash D541 0.790 mm —-0.0213 = GO311 in 1.00 mm 0.0394 in, Torque Specifi ications Part tightened gem. Engine drain plug Plug of oll pump relief valve ‘Timing gear ease x Cylinder block 12 mm bolt head +14 mm bolt head 375 2 37 i pipe x Timing gear ease (Union be 110 8 1 Oi pie «jection pum 110 a " Gil pipe x Timing gear ease (Nut 385 13 18 Oi pipe x Cylinder Block 450 3 a4 Oil siesiner x Timing gear cb5e | 185 13 8 Of strainer x Gylinde block ' 185 13 18 Gil pan x Timing gear case | 185 2 18 (it pan x Cylinder block 185 13 18 Oi pan x Rear of geal retainer 185 a 18 Oil cooler x Oil cooler cas¢ 130 13 it seoler cose x Cylinder block 195 13 18 Si titer beocket x Cylinder block 375. 2 37 Plug of oil cooler relief valve . 500 36 ag Plug of oil fier retot valve 500 (OW nozzle eneck valve x Cylinder blockA22 SERVICE SPECIFICATIONS — Starting System, Chat STARTING SYSTEM "Pre-heating ] system 38 (Super glow type) at 20°C 468°F) | Approx. 2 seconde 8, 38 Fixed dolay type) 15 ~ 195 seconds 498, 198, 138-T St water temp, sensor disconnected 12V type 20 seconds 24¥ type 14 seconds Starter Rated voltoge and output power 12V 28 kw 24 45 kw Nosload characteristic Ampere | 180A or less at 11 V 80 A or less at 23 V rpm 3.500 rpm or more = Brush length To 205mm = 0.807 in - te | isome gstze | Spring installed load = STO. 32-40 kg = 2.4-88b,31-39N) | Commutator Outer diameter STD 36 mm, 1.42 in = Limit 35 mm 1.BB in. = Undercut depth STD 07 mm 0028 in = Limit 0.2 mm 9.008 in ie Circle runout __Limit 005mm 0.0020 ia, = CHARGING SYSTEM Battery specific gravity See page A-2 Drive belt tension or deflection See page A-2 Alternator Rated output 12V GOA 12V 45a 12V 50A 12V 558A 24V 204 28V 25a 24V 30A 24V 554 Rotor coil resistance vela IC regutator 1viype | 38-210 2eviype | 188-1920 w/ IC regulator 12V tye | 28-300 2aviype | 88-920 Stip ring diameter sto | 323.~325mm 1.272 ~ 1.280 in, Limit | 32.1.mm 1.264 in | Brush exposed length sto | 200mm o7e7 ‘ Limit | 55 mm 0.217 in ‘Alternator Regulating voltage at 25°C (77°F) regulator Wio IC regulator 12viyee | 138-149 2aviype | 270-280 WAC regutptor iavivee | 138 -144V ‘ _2avwpe | 273 -285v