SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.] 1.3 Fuel system Table 2-3 Maintenance service data table - Fuel system Unit: mm [in.] 1.4 Lubrication system Table 2-4 Maintenance service data table - Lubrication system Unit: mm [in.] 2-6 Inspection point Nominal Standard Limit Remark Main bearing Clearance between main bearing and crank- shaft journal 0.050 to 0.110 [0.0020 to 0.0043] 0.200 [0.0079] crank journal outside diameter (ø 78 [3.0709]) -0.9 [-0.0354] Replace bearings before limit is reached.
Regrind crank journal and use next undersize bearings if limit is exceeded; -0.25 [-0.0098], -0.50 [-0.0197], -0.75 [-0.0295] Crankcase Flatness of top surface 0.05 [0.0020] or less 0.20 [0.0079] Reface minimum thickness. Tappet guide hole inside diameter 14.000 to 14.018 [0.5512 to 0.5519] 14.100 [0.5551] Clearance between tappet and tappet guide hole 0.016 to 0.052 [0.0006 to 0.0020] 0.08 [0.0031] If the diameter is the limit or more, replace tappet. Inspection point Nominal Standard Limit Remark Fuel injection nozzle Valve opening pres- sure 11.77 MPa {120 kgf/cm²} [1707 psi] 11.77 to 12.75 MPa {120 to 130 kgf/cm²} [1707 to 1849 psi] Make shim adjustment.
Pressure varies by 1 MPa {10 kgf/cm²} [142 psi] per 0.1 [0.004] thickness of shim. Spray cone angle 0° Check nozzle with a hand tester (at fuel oil temperature 20°C [68°F]). Replace the noz- zle tip if the spray pattern is still bad after washing in clean fuel oil. Nozzle valve seat oil sealing Seat shall hold a test pressure lower than valve opening pressure by 2 MPa {20 kgf/cm²} [285 psi] for 10 seconds. Wash in clean fuel oil or replace nozzle tip. Inspection point Nominal Standard Limit Remark Oil pump Clearance between outer rotor and case 0.20 to 0.30 [0.0079 to 0.0118] 0.50 [0.0197] Replace pump assembly.
Main shaft outside diameter (between case) ø 16 [0.63] 15.985 to 16.000 [0.6293 to 0.6299] Main shaft outside diameter (between oil pump bushing) ø 14 [0.55] 13.957 to 13.975 [0.5495 to 0.5502] Clearance between main shaft and pump case 0.032 to 0.074 [0.0013 to 0.0029] 0.150 [0.0059] Replace pump case or replace pump assembly. Clearance between main shaft and oil pump bushing 0.025 to 0.111 [0.0010 to 0.0044] 0.200 [0.0079] Replace oil pump bush- ing or replace pump assembly. Clearance between inner rotor and outer rotor 0.13 to 0.15 [0.0051 to 0.0059] 0.20 [0.0079] Replace outer rotor and shaft assembly.
Rotor and case end play 0.04 to 0.09 [0.0016 to 0.0035] 0.15 [0.0059] Replace pump assembly. Relief valve Valve opening pressure 0.35 MPa {3.6 kgf/cm²} [51.20 psi] 0.35 ± 0.05 MPa {3.5 ± 0.5 kgf/cm²} [49.78 ± 7.11 psi] Safety valve Valve opening pressure 1.1 MPa {11 kgf/cm²} [157 psi]