Page 1737 of 2267

VA LV E
Unit: mm (in)
SEM188
Valve head diameter ªDº
Intake 39.0 - 39.3 (1.535 - 1.547)
Exhaust 32.0 - 32.3 (1.260 - 1.272)
Valve length ªLº
Intake99.53 - 99.97
(3.9185 - 3.9358)
Exhaust99.38 - 99.82
(3.9126 - 3.9299)
Valve stem diameter ªdº
Intake6.965 - 6.980
(0.2742 - 0.2748)
Exhaust6.945 - 6.960
(0.2734 - 0.2740)
Valve seat angle ªaº 45É30¢
Valve margin ªTº limit 0.5 (0.020)
Valve stem end surface grinding
limit0.5 (0.020)
Valve spring
Inner Outer
Free height mm (in)
Intake 36.57 (1.4398) 42.25 (1.6634)
Exhaust 41.27 (1.6248) 49.35 (1.9429)
Pressure
N (kg, lb)
at heightmm (in)
Intake233.21
(23.78, 52.43)
at 22.2 (0.874)437.69
(44.63, 98.41)
at 25.7 (1.012)
Standard
Exhaust233.4
(23.8, 52.5)
at 22.2 (0.874)437.4
(44.6, 98.3)
at 25.7 (1.012)
Intake208.01
(21.21, 46.77)
at 22.2 (0.874)392.28
(40.00, 88.20)
at 25.7 (1.012)
Limit
Exhaust208.69
(21.28, 46.92)
at 22.2 (0.874)390.42
(39.81, 87.78)
at 25.7 (1.012)
Out-of-square mm (in)
IntakeLess than 1.6
(0.063)Less than 1.8
(0.071)
ExhaustLess than 1.8
(0.071)Less than 2.2
(0.087)
Valve guide
Unit: mm (in)
Standard Service
Valve guide
Outer diameter11.023 - 11.034
(0.4340 - 0.4344)11.223 - 11.234
(0.4418 - 0.4423)
Valve guide
Inner diameter
(Finished size)7.000 - 7.015
(0.2756 - 0.2762)
Cylinder head valve
guide hole diameter10.985 - 10.996
(0.4325 - 0.4329)11.185 - 11.196
(0.4404 - 0.4408)
Interference fit of valve
guide0.027 - 0.049
(0.0011 - 0.0019)
Standard Max. tolerance
Stem to guide clearance
Intake0.020 - 0.050
(0.0008 - 0.0020)0.10 (0.0039)
Exhaust0.040 - 0.070
(0.0016 - 0.0028)0.10 (0.0039)
Valve deflection limit 0.1 (0.004)
SERVICE DATA AND SPECIFICATIONS (SDS)CD20T
Inspection and Adjustment (Cont'd)
EM-197
Page 1738 of 2267
Valve seat resurfacing VALVE LIFTER
Unit: mm (in)
Valve lifter outer diameter
Standard34.959 - 34.975
(1.3763 - 1.3770)
Cylinder head valve lifter hole
diameter34.998 - 35.018
(1.3779 - 1.3787)
Clearance
Standard0.023 - 0.059
(0.0009 - 0.0023)
Limit 0.1 (0.004)
AVAILABLE SHIMS
Thickness mm (in) Identification mark
2.20 (0.0866) 220
2.25 (0.0886) 225
2.30 (0.0906) 230
2.35 (0.0925) 235
2.40 (0.0945) 240
2.45 (0.0965) 245
2.50 (0.0984) 250
2.55 (0.1004) 255
2.60 (0.1024) 260
2.65 (0.1043) 265
2.70 (0.1063) 270
2.75 (0.1083) 275
2.80 (0.1102) 280
2.85 (0.1122) 285
2.90 (0.1142) 290
VALVE CLEARANCE
Unit: mm (in)
For adjusting
HotCold*
(reference data)
Intake0.25 - 0.35
(0.010 - 0.014)0.20 - 0.30
(0.008 - 0.012)
Exhaust0.39 - 0.49
(0.015 - 0.019)0.33 - 0.43
(0.013 - 0.017)
*: At a temperature of approximately 20ÉC (68ÉF)
Unit: mm (in)
SEM917-B
SEM113FA
SERVICE DATA AND SPECIFICATIONS (SDS)CD20T
Inspection and Adjustment (Cont'd)
EM-198
Page 1739 of 2267

CYLINDER BLOCK
Unit: mm (in)
SEM902-A
Standard Limit
Surface flatness Less than 0.03 (0.0012) 0.10 (0.0039)
Cylinder
boreInner
diameterGrade No. 1
0.2
(0.008) 84.500 - 84.510
(3.3268 - 3.3272)
Grade No. 2
84.510 - 84.520
(3.3272 - 3.3276)
Grade No. 3
84.520 - 84.530
(3.3276 - 3.3279)
Grade No. 4
84.530 - 84.540
(3.3279 - 3.3283)
Grade No. 5
84.540 - 84.550
(3.3283 - 3.3287)
Out-of-
round
(X þ Y)Less than 0.015 (0.0006) 0.04 (0.0016)
Taper
(A þ B)Less than 0.010 (0.0004) 0.04 (0.0016)
Piston to cylinder clear-
ance0.030 - 0.050
(0.0012 - 0.0020)Ð
Main journal inner
diameterGrade No. 0
Ð 56.654 - 56.663
(2.2305 - 2.2308)
Grade No. 1
56.663 - 56.672
(2.2308 - 2.2312)
Grade No. 2
56.672 - 56.680
(2.2312 - 2.2315)
PISTON, PISTON RING AND PISTON PIN
Piston
Unit: mm (in)
Piston
skirt
diam-
eterStandardGrade No. 184.460 - 84.470
(3.3252 - 3.3256)
Grade No. 284.470 - 84.480
(3.3256 - 3.3260)
Grade No. 384.480 - 84.490
(3.3260 - 3.3264)
Grade No. 484.490 - 84.500
(3.3264 - 3.3268)
Grade No. 584.500 - 84.510
(3.3268 - 3.3272)
Oversize0.25 (0.0098)84.710 - 84.760
(3.3350 - 3.3370)
0.5 (0.020)84.960 - 85.010
(3.3449 - 3.3468)
Measure position (From Top) 62 (2.44)
Piston pin hole diameter27.991 - 27.999
(1.1020 - 1.1023)
Piston ring
Unit: mm (in)
Side clearance
To p
Standard 0.020 - 0.040 (0.0008 - 0.0016)
Limit 0.10 (0.0039)
2nd
Standard 0.050 - 0.085 (0.0020 - 0.0033)
Limit 0.10 (0.0039)
Oil
Standard 0.030 - 0.070 (0.0012 - 0.0028)
End gap
To p
Standard
Bore grade 1, 2, 3 0.22 - 0.32 (0.0087 - 0.0126)
Bore grade 4, 5 0.12 - 0.22 (0.0047 - 0.0087)
Limit 1.0 (0.039)
2nd
Standard 0.38 - 0.53 (0.0150 - 0.0209)
Limit 0.7 (0.028)
Oil
Standard 0.30 - 0.55 (0.0118 - 0.0217)
Limit 0.6 (0.024)
SERVICE DATA AND SPECIFICATIONS (SDS)CD20T
Inspection and Adjustment (Cont'd)
EM-199
Page 1740 of 2267

Piston pin
Unit: mm (in)
Piston pin outer diameter27.994 - 28.000
(1.1021 - 1.1024)
Interference fit of piston pin to
pistonþ0.004 to 0 (þ0.0002 to 0)
Piston pin to connecting rod
clearance0.025 - 0.044
(0.0010 - 0.0017)
CONNECTING ROD
Unit: mm (in)
Bend [per 100 mm (3.94 in)]
Standard Less than 0.025 (0.0010)
Torsion
Standard Less than 0.025 (0.0010)
Piston pin bore dia.28.025 - 28.038
(1.1033 - 1.1039)
Big end play
Limit 0.3 (0.012)
CRANKSHAFT
Unit: mm (in)
Main journal dia.Grade No. 0
52.967 - 52.975
(2.0853 - 2.0856)
Grade No. 1
52.959 - 52.967
(2.0850 - 2.0853)
Grade No. 2
52.951 - 52.959
(2.0847 - 2.0850)
Pin journal dia.Grade No. 0
49.968 - 49.974
(1.9672 - 1.9675)
Grade No. 1
49.961 - 49.968
(1.9670 - 1.9672)
Grade No. 2
49.954 - 49.961
(1.9667 - 1.9670)
Out-of-round (X þ Y) and
taper (A þ B)
Standard Less than 0.005 (0.0002)
Runout
Standard Less than 0.05 (0.0020)
Free end play
Standard 0.05 - 0.18 (0.0020 - 0.0071)
Limit 0.3 (0.012)
AVAILABLE MAIN BEARINGS
No. 1, No. 2, No. 4 and No. 5 main bearings
Grade number Thickness ªTº mm (in) Width ªWº mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717) Yellow
1 1.820 - 1.824 (0.0717 - 0.0718) Green
2 1.824 - 1.828 (0.0718 - 0.0720)20.0 (0.787)
17.8 (0.701)*Brown
3 1.828 - 1.832 (0.0720 - 0.0721) Black
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
*: Contacting width
No. 3 main bearings
Grade number Thickness ªTº mm (in) Width ªWº mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717) Yellow
1 1.820 - 1.824 (0.0717 - 0.0718) Green
2 1.824 - 1.828 (0.0718 - 0.0720)27.95 (1.1004)
21.35 (0.8405)*Brown
3 1.828 - 1.832 (0.0720 - 0.0721) Black
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
*: Contacting width
SERVICE DATA AND SPECIFICATIONS (SDS)CD20T
Inspection and Adjustment (Cont'd)
EM-200
Page 1741 of 2267

Main bearing undersize
Unit: mm (in)
Crank journal diameter
STD52.951 - 52.975
(2.0847 - 2.0856)
0.25 (0.0098) undersize52.701 - 52.725
(2.0748 - 2.0758)
Connecting rod bearing undersize
Unit: mm (in)
Crank pin diameter
STDGrade 0 Black49.968 - 49.974
(1.9672 - 1.9675)
Grade 1 Yellow49.961 - 49.968
(1.9670 - 1.9672)
Grade 2 Blue49.954 - 49.961
(1.9667 - 1.9670)
0.08 (0.0031) undersize49.874 - 49.894*
(1.9635 - 1.9643)
0.12 (0.0047) undersize49.834 - 49.854*
(1.9620 - 1.9628)
0.25 (0.0098) undersize49.704 - 49.724*
(1.9568 - 1.9576)
*: Reference value
Bearing clearance
Unit: mm (in)
Main bearing clearance
Standard0.039 - 0.065
(0.0015 - 0.0026)
Connecting rod bearing clearance
Standard0.031 - 0.055
(0.0012 - 0.0022)
TURBOCHARGER
Unit: mm (in)
Rotor shaft
Runout [TIR*] 0.056 - 0.127 (0.0022 - 0.0050)
End play 0.013 - 0.097 (0.0005 - 0.0038)
*: Total indicator reading
MISCELLANEOUS COMPONENTS
Unit: mm (in)
Flywheel
Runout [TIR*] Less than 0.15 (0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)CD20T
Inspection and Adjustment (Cont'd)
EM-201
Page 1742 of 2267
NOTE
SERVICE DATA AND SPECIFICATIONS (SDS)CD20T
EM-202
Page 1743 of 2267

FRONT AXLE &
FRONT SUSPENSION
SECTION
FA
CONTENTS
PRECAUTIONS AND PREPARATION.......................... 2
Precautions ................................................................ 2
Special Service Tools ................................................ 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING................................................... 3
NVH Troubleshooting Chart....................................... 3
FRONT SUSPENSION SYSTEM.................................. 4
ON-VEHICLE SERVICE................................................ 5
Front Axle and Front Suspension Parts .................... 5
Front Wheel Bearing.................................................. 6
Front Wheel Alignment .............................................. 6
Drive Shaft ................................................................. 8FRONT AXLE................................................................ 9
Wheel Hub and Knuckle ........................................... 11
Drive shaft................................................................ 15
FRONT SUSPENSION................................................ 26
Coil Spring and Shock Absorber ............................. 28
Third Link and Upper Link ....................................... 29
Transverse Link and Lower Ball Joint ..................... 32
Stabilizer Bar ........................................................... 32
SERVICE DATA AND SPECIFICATIONS (SDS)........ 34
General Specifications ............................................. 34
Inspection and Adjustment ...................................... 35
FA
Page 1744 of 2267

Precautions
lWhen installing each rubber part, final tightening must
be carried out under unladen condition* with tires on
ground.
*: Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
lWhen removing each suspension part, check wheel
alignment and adjust if necessary.
lUse Tool when removing or installing brake tubes.
lAlways torque brake lines when installing.
Special Service Tools
Tool number
Tool nameDescription
HT72520000
Ball joint remover
NT546
Removing tie-rod outer end and lower
ball joint
a: 33 (1.30)
b: 50 (1.97)
v: 11.5 (0.453) Unit: mm (in)
HT71780000
Spring compressor
NT144
Removing and installing coil spring
GG94310000
Flare nut torque wrench
NT406
Removing and installing brake piping
a: 10 mm (0.39 in)
KV38106700
KV38106800
Differential side oil seal
protector
LH : KV38106700
RH : KV38106800 NT147
Installing drive shaft
IM23600800
Attachment
Wheel alignment
NT148
Measure wheel alignment
a: Screw M24 x 1.5
b: 35 (1.38) dia.
c: 65 (2.56) dia.
d: 56 (2.20)
e: 12 (0.47)Unit: mm (in)
ST35652000
Strut attachment
NT145
Fixing strut assembly
SBR500 GG94310000
PRECAUTIONS AND PREPARATION
FA-2