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< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*
2: Diameter made by intersection point of conic angles “α2” and “α3”
*
3: Machining data
VALVE SPRING
Items Standard Oversize (Service) [0.5 (0.020)]
Cylinder head seat recess diameter “D”Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Valve seat outer diameter “d”Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)
Valve seat interference fitIntake 0.081 - 0.113 (0.0032 - 0.0044)
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Diameter “d1”*
1Intake 34.6 (1.362)
Exhaust 27.7 (1.091)
Diameter “d2”*
2Intake 35.9 - 36.4 (1.413 - 1.433)
Exhaust 29.3 - 29.8 (1.154 - 1.173)
Angle “α1”Intake 60°
Exhaust 60°
Angle “α2”Intake 88°45′ - 90°15′
Exhaust 88°45′ - 90°15′
Angle “α3”Intake 120°
Exhaust 120°
Contacting width “W”*
3Intake 1.0 - 1.4 (0.039 - 0.055)
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Height “h”Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197)
Depth “H”6.0 (0.236)
PBIC2745E
Items Standard
Free height 47.07 mm (1.8531 in)
Installation height 37.00 mm (1.4567 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 27.20 mm (1.0709 in)
Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)
Page 2018 of 5121

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-143
< SERVICE DATA AND SPECIFICATIONS (SDS)
C
D
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Unit: mm (in)
Cylinder BlockINFOID:0000000003802307
CYLINDER BLOCK
Unit: mm (in)
Items Limit
Squareness2.1 (0.083)
Engine VQ25DE VQ35DE
Surface flatnessStandard Less than 0.03 (0.0012)
Limit 0.1 (0.004)
Main bearing housing inner
diameterStandard 63.993 - 64.017 (2.5194 - 2.5203)
Cylinder
boreInner diame-
terStandardGrade No. 1 85.000 - 85.010 (3.3465 - 3.3468) 95.500 - 95.510 (3.7598 - 3.7602)
Grade No. 2 85.010 - 85.020 (3.3468 - 3.3472) 95.510 - 95.520 (3.7602 - 3.7606)
Grade No. 3 85.020 - 85.030 (3.3472 - 3.3476) 95.520 - 95.530 (3.7606 - 3.7610)
Wear limit 0.2 (0.008)
Out-of-round
Limit0.015 (0.0006)
Ta p e r 0.010 (0.0004)
Main bearing housing inner diameter
grade (Without bearing)Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 4
Grade No. 763.993 - 63.994 (2.5194 - 2.5194)
63.994 - 63.995 (2.5194 - 2.5195)
63.995 - 63.996 (2.5195 - 2.5195)
63.996 - 63.997 (2.5195 - 2.5196)
63.997 - 63.998 (2.5196 - 2.5196)
63.998 - 63.999 (2.5196 - 2.5196)
63.999 - 64.000 (2.5196 - 2.5197)
64.000 - 64.001 (2.5197 - 2.5197)
64.001 - 64.002 (2.5197 - 2.5198)
64.002 - 64.003 (2.5198 - 2.5198)
64.003 - 64.004 (2.5198 - 2.5198)
64.004 - 64.005 (2.5198 - 2.5199)
64.005 - 64.006 (2.5199 - 2.5199)
64.006 - 64.007 (2.5199 - 2.5200)
64.007 - 64.008 (2.5200 - 2.5200)
64.008 - 64.009 (2.5200 - 2.5200)
64.009 - 64.010 (2.5200 - 2.5201)
64.010 - 64.011 (2.5201 - 2.5201)
64.011 - 64.012 (2.5201 - 2.5202)
64.012 - 64.013 (2.5202 - 2.5202)
64.013 - 64.014 (2.5202 - 2.5202)
64.014 - 64.015 (2.5202 - 2.5203)
64.015 - 64.016 (2.5203 - 2.5203)
64.016 - 64.017 (2.5203 - 2.5203)
Difference in inner diameter
between cylindersStandard Less than 0.03 (0.0012)
JPBIA2238GB
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EM-144
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
AVAILABLE PISTON
VQ25DE
Unit: mm (in)
VQ35DE
Unit: mm (in)
PISTON RING
Items Standard Oversize (Service) [0.2 (0.008)]
Piston skirt diameter “A”Grade No. 1 84.980 - 84.990 (3.3457 - 3.3461) —
Grade No. 2 84.990 - 85.000 (3.3461 - 3.3465) —
Grade No. 3 85.000 - 85.010 (3.3465 - 3.3468) —
Service — 85.180 - 85.210 (3.3535 - 3.3547)
Items Standard Limit
“a” dimension 38.8 (1.528) —
Piston pin hole diameterGrade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)
SEM882E
Items Standard Oversize (Service) [0.2 (0.008)]
Piston skirt diameter “A”Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —
Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —
Service — 95.680 - 95.710 (3.7669 - 3.7681)
Items Standard Limit
“a” dimension 38.0 (1.496) —
Piston pin hole diameterGrade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)
SEM882E
Page 2020 of 5121

SERVICE DATA AND SPECIFICATIONS (SDS)
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< SERVICE DATA AND SPECIFICATIONS (SDS)
C
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P O VQ25DE
Unit: mm (in)
VQ35DE
Unit: mm (in)
PISTON PIN
Unit: mm (in)
CONNECTING ROD
Unit: mm (in)
*: After installing in connecting rod
CRANKSHAFT
Items Standard Limit
Side clearanceTop 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.045 - 0.125 (0.0018 - 0.0049) —
End gapTop 0.20 - 0.30 (0.0079 - 0.0118) 0.54 (0.0213)
2nd 0.31 - 0.46 (0.0122 - 0.0181) 0.67 (0.0264)
Oil (rail ring) 0.20 - 0.50 (0.0079 - 0.0197) 0.95 (0.0374)
Items Standard Limit
Side clearanceTop 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.065 - 0.125 (0.0026 - 0.0049) —
End gapTop 0.23 - 0.28 (0.0091 - 0.0110) 0.49 (0.0193)
2nd 0.33 - 0.43 (0.0130 - 0.0169) 0.90 (0.0354)
Oil (rail ring) 0.20 - 0.45 (0.0079 - 0.0177) 0.95 (0.0374)
Items Standard Limit
Piston pin outer diameterGrade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
ItemsStandard
Limit
VQ25DE VQ35DE
Center distance 147.60 - 147.70 (5.81 - 5.81) 144.15 - 144.25 (5.68 - 5.68) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Connecting rod bushing inner
diameter*Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —
Connecting rod big end diameter (Without
bearing)48.000 - 48.013 (1.8898 - 1.8903) 55.000 - 55.013 (2.1654 - 2.1659) —
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)
Page 2021 of 5121

EM-146
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
*: Total indicator reading
Main BearingINFOID:0000000003802308
MAIN BEARING
Engine VQ25DE VQ35DE
Main journal diameter. “Dm”
gradeStandardGrade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 4
Grade No. 759.975 - 59.974 (2.3612 - 2.3612)
59.974 - 59.973 (2.3612 - 2.3611)
59.973 - 59.972 (2.3611 - 2.3611)
59.972 - 59.971 (2.3611 - 2.3611)
59.971 - 59.970 (2.3611 - 2.3610)
59.970 - 59.969 (2.3610 - 2.3610)
59.969 - 59.968 (2.3610 - 2.3609)
59.968 - 59.967 (2.3609 - 2.3609)
59.967 - 59.966 (2.3609 - 2.3609)
59.966 - 59.965 (2.3609 - 2.3608)
59.965 - 59.964 (2.3608 - 2.3608)
59.964 - 59.963 (2.3608 - 2.3607)
59.963 - 59.962 (2.3607 - 2.3607)
59.962 - 59.961 (2.3607 - 2.3607)
59.961 - 59.960 (2.3607 - 2.3606)
59.960 - 59.959 (2.3606 - 2.3606)
59.959 - 59.958 (2.3606 - 2.3605)
59.958 - 59.957 (2.3605 - 2.3605)
59.957 - 59.956 (2.3605 - 2.3605)
59.956 - 59.955 (2.3605 - 2.3604)
59.955 - 59.954 (2.3604 - 2.3604)
59.954 - 59.953 (2.3604 - 2.3603)
59.953 - 59.952 (2.3603 - 2.3603)
59.952 - 59.951 (2.3603 - 2.3603)
Pin journal diameter. “Dp” grade StandardGrade No. 0 44.968 - 44.974 (1.7704 - 1.7706) 51.968 - 51.974 (2.0460 - 2.0462)
Grade No. 1 44.962 - 44.968 (1.7702 - 1.7704) 51.962 - 51.968 (2.0457 - 2.0460)
Grade No. 2 44.956 - 44.962 (1.7699 - 1.7702) 51.956 - 51.962 (2.0445 - 2.0457)
Center distance “r” 36.61 - 36.69 (1.4413 - 1.4445) 40.66 - 40.74 (1.6008 - 1.6039)
Taper (Difference between “A”
and “B”)
Limit0.002 (0.0001)
Out-of-round (Difference between
“X” and “Y”)0.002 (0.0001)
Crankshaft runout [TIR*]Standard Less than 0.05 (0.0020)
Limit 0.10 (0.0039)
Crankshaft end playStandard 0.10 - 0.25 (0.0039 - 0.0098)
Limit 0.30 (0.0118)
SEM645SBIA0535E
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SERVICE DATA AND SPECIFICATIONS (SDS)
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< SERVICE DATA AND SPECIFICATIONS (SDS)
C
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EM
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Unit: mm (in)
UNDERSIZE
Unit: mm (in)
MAIN BEARING OIL CLEARANCE
Unit: mm (in)
*: Actual clearance
Connecting Rod BearingINFOID:0000000003802309
CONNECTING ROD BEARING
Grade number Thickness Width Identification color Remarks
0 2.000 - 2.003 (0.0787 - 0.0789)
19.9 - 20.1
(0.783 - 0.791)Black
Grade is the same
for upper and lower
bearings. 1 2.003 - 2.006 (0.0789 - 0.0790) Brown
2 2.006 - 2.009 (0.0790 - 0.0791) Green
3 2.009 - 2.012 (0.0791 - 0.0792) Yellow
4 2.012 - 2.015 (0.0792 - 0.0793) Blue
5 2.015 - 2.018 (0.0793 - 0.0794) Pink
6 2.018 - 2.021 (0.0794 - 0.0796) Purple
7 2.021 - 2.024 (0.0796 - 0.0797) White
01UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown
Grade and color are
different for upper
and lower bearings. LWR 2.000 - 2.003 (0.0787 - 0.0789) Black
12UPR 2.006 - 2.009 (0.0790 - 0.0791) Green
LWR 2.003 - 2.006 (0.0789 - 0.0790) Brown
23UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow
LWR 2.006 - 2.009 (0.0790 - 0.0791) Green
34UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue
LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow
45UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink
LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue
56UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple
LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink
67UPR 2.021 - 2.024 (0.0796 - 0.0797) White
LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple
PBIC2619E
Items Thickness Main journal diameter
0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843) Grind so that bearing clearance is the specified value.
Items Standard Limit
Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)
Page 2023 of 5121
EM-148
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
UNDERSIZE
Unit: mm (in)
CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in)
*: Actual clearanceGrade number Thickness Identification color (mark)
0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
2 1.506 - 1.509 (0.0593 - 0.0594) Green
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.
Items Standard Limit
Connecting rod bearing oil clearance 0.020 - 0.045 (0.0008 - 0.0018)* 0.070 (0.0028)
Page 2024 of 5121

EX-1
ENGINE
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SECTION EX
A
EX
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CONTENTS
EXHAUST SYSTEM
PRECAUTION ................ ...............................2
PRECAUTIONS .............................................. .....2
Removal and Installation ..................................... ......2
PREPARATION ............................................3
PREPARATION .............................................. .....3
Commercial Service Tool .................................... ......3
ON-VEHICLE MAINTENANCE .....................4
EXHAUST SYSTEM ...........................................4
Inspection ............................................................ .....4
ON-VEHICLE REPAIR ..................................5
EXHAUST SYSTEM ...........................................5
Exploded View ..................................................... .....5
Removal and Installation ..........................................5
Inspection .................................................................6