ENGINE
DATA, TORQUE & TOOLS1
ENGINE DATA
Rocker shaft
Rocker shaft wear - maximum 0.025 mm..................
Rocker arm shaft to bush clearance - maximum 0.12 mm....
Valve clearance - inlet and exhaust 0.20 mm..............
Oil pump
Outer rotor to housing clearance 0.025 to 0.075 mm................
Inner to outer rotor clearance 0.025 to 0.075 mm..................
Outer rotor end-float 0.026 to 0.135 mm.........................
Relief valve spring free length 68.0 mm..................
Cylinder head
Cylinder head maximum warpage 0.08 mm...............
Maximum movement of valve to guide 0.15 mm...........
Valve stem diameter:
Inlet 7.96 mm......................................
Exhaust 7.94 mm...................................
Valve head stand down:
Inlet 0.81 to 1.09 mm......................................
Exhaust 0.86 to 1.14 mm...................................
Valve seat insert face angle:
Inlet 60° ......................................
Exhaust 45° ...................................
Valve face angle:
Inlet 60°00' to 60°30' ......................................
Exhaust 45°00' to 45°30' ...................................
Valve spring free length 46.28 mm.......................
Timing belt tension on torque wrench
Used belt 12 Nm..................................
New belt 15 Nm...................................
Drive plate - automatic gearbox
Setting height 12.4 mm...............................
ENGINE
DATA, TORQUE & TOOLS3
TORQUE FIGURES
Timing belt tensioner bolt 45 Nm.....................
Timing belt idler pulley nut 45 Nm.....................
Flywheel/drive plate housing plug 12 Nm...............
Timing belt front cover bolts 25 Nm....................
Crankshaft pulley bolt 80 Nm then further 90° ........................
Rocker shaft nuts and bolts 5 Nm then further 50° ....................
Rocker cover nuts 10 Nm...........................
Crankcase breather cyclone unit bolt 9 Nm............
Rear timing cover bolts 25 Nm.......................
Oil pressure relief valve plug 17 Nm...................
Flywheel bolts 146 Nm..............................
Drive plate bolts 146 Nm.............................
Drive plate to starter ring gear bolts 25 Nm..............
Flywheel/drive plate housing bolts 45 Nm...............
Coolant outlet elbow bolts 9 Nm.....................
Thermostat housing bolts 25 Nm.....................
Oil filter head bolts 45 Nm...........................
Cylinder head bolts:
Stage 1 40 Nm...................................
Stage 2 Further 60° ...................................
Stage 3 Further 60° ...................................
Stage 4 - Bolts 1, 2, 7, 8, 9, 10, 15, 16, 17 and 18
onlyFurther 20°
......................................
Sump drain plug 35 Nm............................
Oil sump bolts 25 Nm..............................
Oil pick-up pipe bolts:
To main bearing cap 9 Nm.........................
To timing belt rear cover 25 Nm......................
Oil drain pipe bolts 25 Nm...........................
Fuel pump timing gear to hub plate bolts 25 Nm..........
Injector clamp nut 25 Nm...........................
Spill return pipe banjo bolts 10 Nm....................
Glow plugs 20 Nm.................................
Brake servo vacuum pump bolts 25 Nm................
Camshaft gear bolt 80 Nm..........................
Spill return pipe to injection pump banjo bolts 25 Nm......
Mounting bracket to fuel injection pump bolts 25 Nm......
Fuel injection pump and baffle plate to cylinder
block bolts25 Nm
.................................
Crankshaft rear oil seal housing bolts 25 Nm............
Camshaft thrust plate bolts 9 Nm....................
Camshaft oil jet tube 17 Nm.........................
Piston oil jet banjo bolts 17 Nm.......................
Cam follower guide bolts 14 Nm......................
Big-end bearing cap nuts 59 Nm......................
Main bearing cap bolts 133 Nm.......................
