EM -2 ENGINE MECHANICAL SYSTEM

GENERAL
SPECIFICATIONS (D4CB) LCAC0100

DESCRIPTION SPECIFICATION (D4CB) LIMIT

General
Type In-line, DOHC
Number of cylinders 4
Bore 91 mm (3.58 in)
Stroke 96 mm (3.78 in)
Total displacement 2497 cc (121.5 cu.in)
Compression ratio 17.7 : 1
Firing order 1-3-4-2
Valve timing
Intake valve
Opens (BTDC) 8
Closes (ABDC) 38
Exhaust valve
Opens (BBDC) 52
Closes (ATDC) 8
Cylinder head
Flatness of gasket surface 0.15 mm (0.0059 in)
Camshaft
Cam height (LH)
Intake 40.163 mm (1.5812 in)
Exhaust 40.043 mm (1.5765 in)
Cam height (RH)
Intake 39.782 mm (1.5662 in)
Exhaust 40.456 mm (1.5928 in)
Journal outer Diameter 29.964 - 29.980 mm (1.1797 - 1.1803 in)
End play 0.10 - 0.20 mm (0.0039 - 0.0079 in)
Valve
Valve length
Intake 110.55 mm (4.352 in)
Exhaust 110.55 mm (4.352 in)
Stem outer diameter
Intake 6.965 - 6.980 mm (0.2742 - 0.2748 in)
Exhaust 6.935 - 6.950 mm (0.2730 - 0.2736 in)
Face angle 45
Thickness of valve head (margin)
GENERAL EM -3

DESCRIPTION SPECIFICATION (D4CB) LIMIT

Intake 1.8 - 2.0 mm (0.071 - 0.079 in)
Exhaust 1.8 - 2.0 mm (0.071 - 0.079 in)
Valve stem to valve guide clearance
Intake 0.020 - 0.050 mm (0.0008 - 0.0020 in) 0.1mm (0.0039in)
Exhaust 0.050 - 0.080 mm (0.0020 - 0.0031 in) 0.15mm (0.0059in)
Valve guide
Length
Intake 43.3 mm (1.705 in)
Exhaust 39.4 mm (1.551 in)
Valve seat
Width of seat contact
Intake 1.5 mm (0.059 in)
Exhaust 1.7 mm (0.067 in)
Seat angle
Intake 45
Exhaust 45
Valve spring
Free length 48.2 mm (1.898 in)
Load 258 ¡ 12 N/38 mm
(26.3 ± 1.2 kg/38 mm,
569 ¡ 26 lb/1.496 in)
505.5 ¡ 24 N/28.8 mm
(51.5 ± 2.4 kg /28.8 mm,
1114.4 ¡ 53 lb/1.134 in)
Cylinder block
Cylinder bore 91.000 - 91.030 mm (3.5827 - 3.5839 in)
Flatness of gasket surface 0.05 mm (0.0020 in)
Piston
Piston outer diameter 90.910 - 90.940 mm (3.5791 - 3.5803 in)
Piston to cylinder clearance 0.080 - 0.100 mm (0.0031 - 0.0039 in)
Ring groove width
No. 1 ring groove 2.378 - 2.398 mm (0.0936 - 0.0944 in)
No. 2 ring groove 2.04 - 2.06 mm (0.0803 - 0.0811 in)
Oil ring groove 3.03 - 3.05 mm (0.1193 - 0.1201 in)
EM -4 ENGINE MECHANICAL SYSTEM

DESCRIPTION SPECIFICATION (D4CB) LIMIT

Piston ring
Side clearance
No. 2 ring 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Oil ring 0.04 - 0.08 mm (0.0016 - 0.0031 in)
End gap
No. 1 ring 0.25 - 0.40 mm (0.0098 - 0.0157 in)
No. 2 ring 0.50 - 0.70 mm (0.0197 - 0.0276 in)
Oil ring 0.20 - 0.40 mm (0.0079 - 0.0157 in)
Piston pin
Piston pin outer diameter 32.993 - 32.998 mm (1.2989 - 1.2991 in)
Piston pin hole inner diameter 33.000 - 33.005 mm (1.2992 - 1.2994 in)
Piston pin hole clearance 0.002 - 0.012 mm (0.0001 - 0.0005 in)
Connecting rod small end hole inner diameter 33.020 - 33.033 mm (1.3000 - 1.3005 in)
Connecting rod small end hole clearance 0.022 - 0.040 mm (0.0009 - 0.0016 in)
Connecting rod
Connecting rod big end inner diameter 60.000 - 60.018 mm (2.3622 - 2.3629 in)
Connecting rod bearing oil clearance 0.024 - 0.042 mm (0.0009 - 0.0016 in) 0.1mm(0.0039in)
Crankshaft
Main journal outer diameter 66.982 - 67.000 mm (2.6371 - 2.6378 in)
Pin journal outer diameter 56.982 - 57.000 mm (2.2434 - 2.2441 in)
Main bearing oil clearance 0.024 - 0.042 mm (0.0009 - 0.0016 in) 0.1mm(0.0039in)
End play 0.05 - 0.25 mm (0.0020 - 0.0098 in)
Flywheel
Runout 0.13mm(0.0051in)
Oil pump
Side clearance
Inner rotor 0.040 - 0.085 mm (0.0016 - 0.0033 in)
Outer rotor 0.050 - 0.100 mm (0.0020 - 0.0039 in)
Body clearance 0.100 - 0.176 mm (0.0039 - 0.0069 in)
Relief valve opening pressure 784.5 ¡ 78.4 Kpa
(8 ¡ 0.8 kg/cm2, 113.8 ¡ 11.3 psi)
Balance shaft
Front journal outer diameter 48.975 - 49.000 mm (1.9281 - 1.9291 in)
Rear journal outer diameter 47.965 - 47.990 mm (1.8884 - 1.8894 in)
Front bush inner diameter 49.050 - 49.080 mm (1.9311 - 1.9323 in)
Rear bush inner diameter 48.050 - 48.080 mm (1.8917 - 1.8929 in)
Fornt bush oil clearance 0.050 - 0.105 mm (0.0020 - 0.0041 in)
Rear bush oil clearance 0.060 - 0.115 mm (0.0024 - 0.0045 in)
GENERAL EM -5

DESCRIPTION SPECIFICATION (D4CB) LIMIT

Engine oil
Oil quantity (Total) 8.2 L
Oil quantity (Oil pan) 7.4 L
Oil quality Above CE
Cooling method
Cooling system Forced circulation with cooling fan
Coolant quantity 10L
Thermostat
Type Wax pellet type
Opening temperature 82 C (180 F)
Closing temperature 77 C (171 F)
Pull opening temperature 95 C (203 F)
Radiator cap
Main valve opening pressure 107.9¡ 14.7 Kpa
(1.1¡ 0.15 kg/cm2, 15.6¡ 2.1 psi)
Main valve closing pressure 83.4 Kpa (0.85 kg/cm2, 12.1 psi)
Vaccum valve opening pressure -6.86 Kpa (-0.07 kg/cm2, -1.00 psi)
Water temperature sensor
Type Thermister type
Resistance
20 C (68 F) 2.45 ¡ 0.14 k
80 C (176 F) 0.3222 k
EM -6 ENGINE MECHANICAL SYSTEM

TIGHTENING TORQUE LCAC0200

* Bolt size = Diameter x Length

Quan- Tightening torque

ITEM tity
N-m Kg-m lb-ft
Main bearing cap bolt 10 127.5 - 137.3 13 - 14 94.0 - 101.3
Connecting rod cap nut 8 58.8 - 0 + 34.3 6.0 - 0 + 3.5 43.4 - 0 + 25.3
+ 60 ~ 64 + 60 ~ 64 + 60 ~ 64
Oil jet bolt 4 29.4 - 34.3 3.0 - 3.5 21.7 - 25.3
Crank shaft pulley bolt 1 274.6 - 294.2 28 - 30 202.5 - 217.0
Rear oil seal case bolt 5 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Rear plate bolt 2 7.8 - 9.8 0.8 - 1.0 5.8 - 7.2
Flywheel bolt 8 127.5 - 137.3 13 - 14 94.0 - 101.3
Water pump bolt (8 x 30) 5 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Water pump bolt (8 x 45) 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Oil cooler fixing nut 4 17.7 - 24.5 1.8 - 2.5 13.0 - 18.1
Oil cooler cover bolt (8 x 35 ) 8 19.6 - 25.5 2.0 - 2.6 14.5 - 18.8
Oil cooler cover bolt (8 x 60) 3 19.6 - 25.5 2.0 - 2.6 14.5 - 18.8
Oil pump bolt (8 x 22) 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Oil pump bolt (10 x 35) 1 42.2 - 53.9 4.3 - 5.5 31.1 - 39.8
Oil pump bolt (10 x 60) 1 42.2 - 53.9 4.3 - 5.5 31.1 - 39.8
Oil screen bolt 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Oil feed pipe bolt 3 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Oil filter assembly 1 21.6 - 24.5 2.2 - 2.5 15.9 - 18.1
Oil pan bolt 22 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Oil level gauge bolt 1 11.8 - 14.7 1.2 - 1.5 8.7 - 10.8
Bed plate bolt (6 x 18) 3 7.8 - 11.8 0.8 - 1.2 5.8 - 8.7
Bed plate bolt (6 x 30) 13 7.8 - 11.8 0.8 - 1.2 5.8 - 8.7
Bed plate bolt (8 x 45) 8 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Bell housing cover bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Oil pressure switch 1 14.7 - 21.6 1.5 - 2.2 10.8 - 15.9
Cylinder head cover bolt 16 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Camshaft cap bolt 20 13.7 - 14.7 1.4 - 1.6 10.1 - 10.8
Cylinder head bolt 18 49.0+120 +90 5.0 + 120 +90 36.2+120 +90
TDC sensor bolt 1 6.9-10.8 0.7-1.1 5.1-8.0
Water temperature sensor 1 29.4 - 39.2 3.0 - 4.0 21.7 - 28.9
Glow plug 4 14.7 - 19.6 1.5 - 2.0 10.8 - 14.5
Glow plug plate nut 4 0.8 - 1.5 0.08 - 0.15 0.6 - 1.1
Engine hanger bolt 4 18.6 - 28.4 1.9 - 2.9 13.7 - 21.0
Thermostat housing bolt 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
GENERAL EM -7

Quan- Tightening torque

ITEM tity
N-m Kg-m lb-ft
Exhaust manifold lock nut 8 16.7 - 25.5 1.7 - 2.6 12.3 - 18.8
Exhaust manifold heat protector bolt 3 14.7 - 21.6 1.5 - 2.2 10.8 - 15.9
Turbo charger nut 3 49.0 - 68.6 5.0 - 7.0 36.2 - 50.6
Turbo charger fitting nut 4 26.5 - 31.4 2.7 - 3.2 19.5 - 23.1
Turbo charger oil return pipe bolt 2 7.8 - 9.8 0.8 - 1.0 5.8 - 7.2
Turbo charger oil inlet pipe bolt 2 13.7 - 18.6 1.4 - 1.9 10.1 - 13.7
Turbo charger water inlet pipe bolt 2 34.3 - 49.0 3.5 - 5.0 25.3 - 36.2
Turbo charger heat protector bolt 3 14.7 - 21.6 1.5 - 2.2 10.8 - 15.9
Intake manifold bolt (8 x 112) 4 14.7 - 19.6 1.5 - 2.0 10.8 - 14.5
Intake manifold bolt (8 x 32) 2 14.7 - 19.6 1.5 - 2.0 10.8 - 14.5
Intake manifold nut 4 14.7 - 19.6 1.5 - 2.0 10.8 - 14.5
EGR valve bolt 2 16.7 - 25.5 1.7 - 2.6 12.3 - 18.8
EGR pipe nut 4 16.7 - 25.5 1.7 - 2.6 12.3 - 18.8
Timing chain lower under cover bolt (6 x 14) 4 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain lower under cover bolt (8 x 22) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lower under cover bolt (8 x 30) 3 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lower under cover bolt (8 x 40) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
LH balance shaft driven gear bolt 1 33.3 - 39.2 3.4 - 4.0 24.6 - 28.9
LH balance shaft sprocket nut 1 49.0 - 58.8 5.0 - 6.0 36.2 - 43.4
RH balance shaft sprocket bolt 1 33.3 - 39.2 3.4 - 4.0 24.6 - 28.9
Timing chain guide “A” bolt (upper) 1 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain guide “A” bolt (lower) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lever “A” bolt 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain auto tensioner “A” bolt 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain guide “B” (1) bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain guide “B” (2) bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain auto tensioner “B” bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain lower front cover bolt (8 x 22) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lower front cover bolt (8 x 40) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lower front cover bolt (8 x 50) 6 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lower front cover bolt (8 x 70) 6 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain lower front cover bolt (8 x 80) 4 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain upper under cover bolt (6 x 14) 4 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain upper under cover bolt (6 x 22) 9 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain upper under cover bolt (8 x 22) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain upper under cover bolt (8 x 40) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain upper under cover nut 1 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain guide “C” (1) bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
EM -8 ENGINE MECHANICAL SYSTEM

Quan- Tightening torque

ITEM tity
N-m Kg-m lb-ft
Timing chain guide “C” (2) bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Timing chain lever “C” bolt 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Timing chain auto tensioner “C” bolt 2 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
High pressure pump sprocket nut 1 64.7 - 74.5 6.6 - 7.6 47.7 - 55.0
Camshaft sprocket bolt 2 93.2 - 117.7 9.5 - 12 68.7 - 86.8
Timing chain upper front cover bolt 9 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
High pressure pump bracket bolt (8 x 35) 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
High pressure pump bracket bolt (8 x 38) 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
High pressure pump fixing nut 3 14.7 - 19.6 1.5 - 2.0 10.8 - 14.5
Common rail fixing bolt 3 14.7 - 21.6 1.5 - 2.2 10.8 - 15.9
Injector clamp bolt 4 27.5 - 33.3 2.8 - 3.4 20.3 - 24.6
High pressure pipe (pump to rail) 1 24.5 - 28.4 2.5 - 2.9 18.1 - 21.0
High pressure pipe (injector to rail) 4 24.5 - 28.4 2.5 - 2.9 18.1 - 21.0
Water pump pulley nut 4 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7
Alternator bracket bolt (8 x 60) 2 18.6 - 27.5 1.9 - 2.8 13.7 - 20.3
Alternator bracket bolt (8 x 35) 2 18.6 - 27.5 1.9 - 2.8 13.7 - 20.3
Alternator fixing bolt & nut (upper) 1 18.6 - 27.5 1.9 - 2.8 13.7 - 20.3
Alternator fixing bolt & nut (lower) 1 18.6 - 27.5 1.9 - 2.8 13.7 - 20.3
Power steering pump bracket bolt (8 x 30) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Power steering pump bracket bolt (8 x 40) 3 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Power steering pump bracket bolt (8 x 75) 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Power steering pump fixing bolt (upper) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Power steering pump fixing bolt (lower) 1 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Air conditioner compressor fixing bolt 4 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Drive belt pulley fixing bolt 3 47.1 - 53.0 4.8 - 5.4 34.7 - 39.1
Drive belt auto tensioner fixing bolt 1 47.1 - 53.0 4.8 - 5.4 34.7 - 39.1
Starter fixing bolt 2 26.5 - 33.3 2.7 - 3.4 14.5 - 24.6
Engine support bracket bolt 2 47.1 - 51.0 4.8 - 5.2 34.7 - 37.6