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SERVICING SPECIFICATIONS
(1) ENGINE BODY
Item Factory Specification Allowable Limit
Lubricating oil capacity 2.5 L
Z482-E2B 0.66 U.S.gals.
0.55 lmp.gals.
3.8 L
Oil pan depth D662-E2B
1.0 U.S.gals.
121 mm (4.76 in.) D722-E2B
0.84 lmp.gals.
3.1 L
D782-E2B 0.82 U.S.gals.
0.68 lmp.gals.
2.1 L
Z482-E2B 0.55 U.S.gals.
0.46 lmp.gals.
2.5 L
Z602-E2B 0.66 U.S.gals.
Oil pan depth 0.55 lmp.gals.
101 mm (3.98 in.)
3.2 L
D662-E2B
0.85 U.S.gals.
D722-E2B 0.70 lmp.gals.
3.7 L
D902-E2B 0.98 U.S.gals.
0.81 lmp.gals.
Cylinder head surface

0.05 mm / 500 mm
Flatness All models
0.0020 in. / 19.69 in.

Compression pressure
Z482-E2B 2.84 to 3.24 MPa 2.26 MPa
D662-E2B
29.0 to 33.0 kgf/cm2 23.0 kgf/cm2
D722-E2B
D782-E2B 412 to 469 psi 327 psi

3.53 to 4.02 MPa 2.55 MPa

Z602-E2B
36.0 to 41.0 kgf/cm2 26.0 kgf/cm2
D902-E2B
512 to 583 psi 370 psi

Top clearance

0.50 to 0.70 mm
All models
0.0197 to 0.0276 in.

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Item Factory Specification Allowable Limit

Valve clearance (When cold)

0.145 to 0.185 mm
All models
0.00571 to 0.00728 in.

Valve & valve seat

0.785 rad.
Face angle (A) All models
45°

0.785 rad.
Seat angle (B) All models
B 45°
C
A
2.12 mm
Seat width (C) All models
0.0835 in.

Valve stem to valve guide

0.030 to 0.057 mm 0.1 mm
Clearance All models
0.00118 to 0.00224 in. 0.0039 in.

5.968 to 5.980 mm
Valve stem O.D. All models
0.23496 to 0.23543 in.

6.010 to 6.025 mm
Valve guide I.D. All models
0.23661 to 0.23720 in.

Valve recessing

-0.10 mm (Protrusion) to
0.10 mm (Recessing) 0.3 mm (Recessing)
All models
-0.0039 in. (Protrusion) to 0.0118 in. (Recessing)
0.0039 in. (Recessing)

Valve spring
31.3 to 31.8 mm 28.4 mm
Free length (A) All models
1.232 to 1.252 in. 1.118 in.
B
1.2 mm
Tilt (B) All models
0.047 in.
A
64.7 N / 27.0 mm 54.9 N / 27.0 mm
Setting load / 6.6 kgf / 27.0 mm 5.6 kgf / 27.0 mm
Setting length All models
14.6 lbs / 1.063 in. 12.3 lbs / 1.063 in.

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Item Factory Specification Allowable Limit

Rocker arm shaft to rocker arm
0.016 to 0.045 mm 0.15 mm
Oil clearance All models
0.00063 to 0.00177 in. 0.0059 in.

Rocker arm shaft 10.473 to 10.484 mm

All models
O.D. 0.41232 to 0.41276 in.

10.500 to 10.518 mm
Rocker arm I.D. All models 0.41339 to 0.41410 in.

Push rod

0.25 mm
Alignment All models
0.0098 in.

Tappet to tappet guide

0.016 to 0.052 mm 0.10 mm
Oil clearance All models
0.00063 to 0.00205 in. 0.0039 in.

17.966 to 17.984 mm
Tappet O.D. All models
0.70732 to 0.70803 in.

18.000 to 18.018 mm
Tappet guide I.D. All models
0.70866 to 0.70937 in.

Timing gear Backlash (Crank 0.043 to 0.124 mm 0.15 mm

All models
gear to idle gear) 0.00169 to 0.00488 in. 0.0059 in.

Backlash (Idle gear All models 0.047 to 0.123 mm 0.15 mm

to cam gear) 0.00185 to 0.00484 in. 0.0059 in.

Backlash (Idle gear 0.046 to 0.124 mm 0.15 mm

to injection pump gear) All models 0.00181 to 0.00488 in. 0.0059 in.
Backlash (Crank gear 0.041 to 0.123mm 0.15 mm
All models
to oil pump drive gear) 0.00161 to 0.00484 in. 0.0059 in.
Idle gear

0.20 to 0.51 mm 0.8 mm

Side clearance All models
0.0079 to 0.0201 in. 0.0315 in.

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Item Factory Specification Allowable Limit

Idle gear shaft to idle gear bushing
0.020 to 0.084 mm 0.1 mm
Oil clearance All models
0.00079 to 0.00331 in. 0.0039 in.

19.967 to 19.980 mm
Idle gear shaft O.D. All models
0.78610 to 0.78661 in.

Idle gear bushing All models 20.000 to 20.051 mm

I.D. 0.78740 to 0.78941 in.

Camshaft

Alignment All models 0.01 mm

0.0004 in.

Camshaft

0.15 to 0.13 mm 0.5 mm

Side clearance All models
0.0059 to 0.0122 in. 0.0197 in.

Cam
Height 26.88 mm 26.83 mm
(Intake) All models
1.0583 in. 1.0563 in.

Height 26.88 mm 26.83 mm

(Exhaust) All models
1.0583 in. 1.0563 in.

Camshaft journal to cylinder block bore

0.050 to 0.091 mm 0.15 mm
Oil clearance All models
0.00197 to 0.00358 in. 0.0059 in.

Camshaft journal 32.934 to 32.950 mm

All models
O.D. 1.29661 to 1.29724 in.

Cylinder block 33.000 to 33.025 mm

All models
bore I.D. 1.29921 to 1.30020 in.

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Item Factory Specification Allowable Limit

Piston pin bore

20.000 to 20.013 mm 20.05 mm

Piston pin bore I.D. All models
0.78740 to 0.78791 in. 0.7894 in.

Piston pin to small end bushing

0.014 to 0.038 mm 0.10 mm
Oil clearance All models
0.00055 to 0.00150 in. 0.0039 in.

20.002 to 20.011 mm
Piston pin O.D. All models
0.78748 to 0.78783 in.

Small end bushing 20.025 to 20.040 mm

All models
I.D. 0.78839 to 0.78897 in.

Piston pin to small end bushing

(Spare parts) 0.015 to 0.075 mm 0.15 mm
Oil clearance All models
0.00059 to 0.00295 in. 0.0059 in.

Small end bushing 20.026 to 20.077 mm

All models
I.D. 0.78843 to 0.79043 in.

Piston ring Z482-E2B

0.15 to 0.30 mm 1.20 mm
D662-E2B
0.0059 to 0.0118 in. 0.0472 in.
D772-E2B
Ring gap
(Top ring) 0.25 to 0.40 mm 1.25 mm
D782-E2B
0.0098 to 0.0157 in. 0.0492 in.
Z602-E2B 0.20 to 0.35 mm 1.25 mm
D902-E2B 0.0079 to 0.0138 in. 0.0492 in.
Z482-E2B
0.30 to 0.45 mm 1.20 mm
D662-E2B
0.0118 to 0.0177 in. 0.0472 in.
D722-E2B
Ring gap
0.25 to 0.40 mm 1.25 mm
(Second ring) D782-E2B
0.0098 to 0.0157 in. 0.0492 in.
Z602-E2B 0.35 to 0.50 mm 1.25 mm
D902-E2B 0.0138 to 0.0197 in. 0.0492 in.
Z482-E2B
0.15 to 0.30 mm 1.20 mm
D662-E2B
0.0059 to 0.0188 in. 0.0472 in.
D722-E2B
Ring gap 0.15 to 0.30 mm 1.25 mm
(Oil ring) D782-E2B
0.0059 to 0.0118 in. 0.0492 in.
Z602-E2B 0.20 to 0.35 mm 1.25 mm
D902-E2B 0.0079 to 0.0138 in. 0.0492 in.

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Item Factory Specification Allowable Limit

Piston ring groove to piston ring Z482-E2B
0.085 to 0.115 mm 0.15 mm
D662-E2B
0.0033 to 0.0045 in. 0.0059 in.
Clearance D722-E2B
(Second ring)
D782-E2B
0.090 to 0.120 mm 0.15 mm
Z602-E2B
0.00354 to 0.00472 in. 0.0059 in.
D902-E2B
Z482-E2B
0.020 to 0.060 mm 0.15 mm
D662-E2B
0.0008 to 0.0024 in. 0.0059 in.
Clearance D722-E2B
(Oil ring) D782-E2B
0.04 to 0.08 mm 0.15 mm
Z602-E2B
0.0016 to 0.0031 in. 0.0059 in.
D902-E2B
Connecting rod

0.05 mm
Alignment All models
0.0020 in.

Crankshaft

0.02 mm
Alignment All models
0.0008 in.

Crankshaft journal to crankshaft 0.034 to 0.106 mm 0.2 mm

Oil clearance All models
bearing 1 0.00134 to 0.00417 in. 0.0079 in.
Z482-E2B
D662-E2B 39.934 to 39.950 mm
Crankshaft journal D722-E2B 1.57221 to 1.57284 in.
O.D. D782-E2B
Z602-E2B 43.934 to 43.950 mm
D902-E2B 1.72968 to 1.73031 in.
Z482-E2B
D662-E2B 39.984 to 40.040 mm
Crankshaft bearing 1 D722-E2B 1.57417 to 1.57638 in.
I.D. D782-E2B
Z602-E2B 43.984 to 44.040 mm
D902-E2B 1.73165 to 1.73386 in.

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Item Factory Specification Allowable Limit

Crankshaft journal to crankshaft
0.028 to 0.059 mm 0.2 mm
bearing 3 (Intermediate) Oil clearance All models
0.00110 to 0.00232 in. 0.0079 in.

Z482-E2B
D662-E2B 39.934 to 39.950 mm
D722-E2B 1.57221 to 1.57284 in.
Crankshaft journal D782-E2B
O.D.
Z602-E2B 43.934 to 43.950 mm
D902-E2B 1.72968 to 1.73031 in.
Z482-E2B
D662-E2B 39.978 to 39.993 mm
D722-E2B 1.57394 to 1.57453 in.
Crankshaft bearing 3 D782-E2B
I.D.
Z602-E2B 43.978 to 43.993 mm
D902-E2B 1.73142 to 1.73201 in.

Crankshaft journal to crankshaft

bearing 2 (Flywheel side) 0.028 to 0.059 mm 0.2 mm
Oil clearance All models
0.00110 to 0.00232 in. 0.0079 in.

Crankshaft journal 43.934 to 43.950 mm

All models
O.D. 1.72968 to 1.73031 in.

Crankshaft bearing 2 43.978 to 43.993 mm

All models
I.D. 1.73142 to 1.73201 in.

Crankpin to crankpin bearing

0.020 to 0.051 mm 0.15 mm
Oil clearance All models
0.00079 to 0.00201 in. 0.0059 in.

33.959 to 33.975 mm
Crankpin O.D. All models
1.33697 to 1.33760 in.

Crankpin bearing 33.995 to 34.010 mm

All models
I.D. 1.33840 to 1.33898 in.

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Item Factory Specification Allowable Limit

Crankshaft

0.15 to 0.31 mm 0.5 mm

Side clearance All models
0.0059 to 0.0122 in. 0.0197 in.

Cylinder 64.000 to 64.019 mm 64.169 mm

D662-E2B
2.51968 to 2.52043 in. 2.52634 in.
Z482-E2B
Bore I.D. 67.000 to 67.019 mm 67.169 mm
D722-E2B
(Standard size) 2.63779 to 2.63854 in. 2.64445 in.
D782-E2B
Z602-E2B 72.000 to 72.019 mm 72.169 mm
D902-E2B 2.83464 to 2.83539 in. 2.84130 in.
64.250 to 64.269 mm 64.419 mm
D662-E2B
2.52952 to 2.53027 in. 2.53618 in.
Z482-E2B
Bore I.D. 67.250 to 67.269 mm 67.419 mm
(Oversize) D722-E2B
2.64764 to 2.64839 in. 2.65429 in.
D782-E2B
Z602-E2B 72.250 to 72.269 mm 72.419 mm
D902-E2B 2.84449 to 2.84524 in. 2.85114 in.

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(2) LUBRICATING SYSTEM
Item Factory Specification Allowable Limit
Engine oil pressure
49 kPa
Engine oil pressure
All models 0.5 kgf/cm2
(At idle speed)
7 psi

196 to 441 kPa 147 kPa

Engine oil pressure
All models 2.0 to 4.5 kgf/cm2 1.5 kgf/cm2
(At rated speed)
28 to 64 psi 21 psi

Inner rotor to outer rotor (Oil pump)

0.03 to 0.14 mm
Clearance All models
0.0012 to 0.0055 in.

Outer rotor to pump body (Oil pump)

0.07 to 0.15 mm
Clearance All models
0.0028 to 0.0059 in.

Inner rotor to cover (Oil pump)

0.075 to 0.135 mm
Clearance All models
0.00295 to 0.00531 in.

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(3) COOLING SYSTEM
Item Factory Specification Allowable Limit
Fan belt

7.0 to 9.0 mm
(0.28 to 0.35 in.)
Tension All models deflection at 98 N
(10 kgf, 22 lbs)
of force

Thermostat
Valve opening 69.5 to 72.5 °C
temperature All models
157.1 to 162.5 °F
(At beginning)

Valve opening 85 °C
temperature All models
185 °F
(Opened completely)

Radiator

No water leak at
Water tightness All models 157 kPa
1.6 kgf/cm2
23 psi

Radiator cap

10 seconds or more
for pressure falling
Pressure falling
All models from 88 to 59 kPa
time
(from 0.9 to 0.6 kgf/cm2,
from 13 to 9 psi)

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(4) FUEL SYSTEM
Item Factory Specification Allowable Limit
Injection pump Z482-E2B
0.33 to 0.37 rad.
D662-E2B
(19 to 21°)
D722-E2B
before T.D.C.
(3600 min-1 (rpm))

0.28 to 0.31 rad.

D782-E2B
(16 to 18°)
(3200 min-1 (rpm))
before T.D.C.
Injection timing
Z602-E2B 0.30 to 0.33 rad.
D902-E2B (17 to 19°)
(3200 min-1 (rpm)) before T.D.C.

Z602-E2B 0.33 to 0.37 rad.

D902-E2B (19 to 21°)
(3600 min-1 (rpm)) before T.D.C.

Pump element

13.73 MPa
Fuel Tightness All models 140 kgf/cm2
1991 psi

Delivery valve

10 seconds 5 seconds
13.73 to 12.75 MPa 13.73 to 12.75 MPa
Fuel Tightness All models
140 to 130 kgf/cm2 140 to 130 kgf/cm2
1991 to 1849 psi 1991 to 1849 psi

Injection nozzle

13.73 to 14.71 MPa

Injection pressure All models 140 to 150 kgf/cm2
1991 to 2133 psi

Injection nozzle

No fuel leak at
Valve seat tightness All models 12.75 MPa
130 kgf/cm2
1849 psi

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(5) ELECTRICAL SYSTEM
Item Factory Specification Allowable Limit
Starter
Electromagnetic 28.0 mm 27.0 mm
drive type 1.102 in. 1.063 in.
Commutator O.D.
Planetary gear 30.0 mm 29.0 mm
reduction type 1.181 in. 1.142 in.

Electromagnetic Less than 0.05 mm 0.4 mm

drive type 0.002 in. 0.016 in.
Difference of
commutator O.D's
Planetary gear Less than 0.02 mm 0.05 mm
reduction type 0.0008 in. 0.0020 in.

Starter

0.50 to 0.80 mm 0.20 mm

Mica under cut All models
0.0197 to 0.0315 in. 0.0079 in.

Starter
Electromagnetic 16.0 mm 10.5 mm
drive type 0.630 in. 0.413 in.

Brush length

Planetary gear 14.0 mm 9.0 mm

reduction type 0.551 in. 0.354 in.

Starter

Brush holder
resistance
All models Infinity
(Brush holder -
Holder support)

Starter

Field coil resistance

(Lead - Brush) All models Continuity

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Item Factory Specification Allowable Limit

Starter

Field coil resistance

(Brush - Yoke) All models Infinity

Starter

Armature coil
resistance All models Infinity
(Commutator -
Armature coil core)

Starter

Armature coil
resistance All models Continuity
(Segment -
Segment)

Dynamo

AC 20V or more
No-load output All models
at 5200 min-1 (rpm)

Dynamo

14 to 15 V
Regurating voltage All models
at 5200 min-1 (rpm)

Alternator

Stator resistance All models Less than 1.0

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Item Factory Specification Allowable Limit

Alternator

Rotor resistance All models 2.9

Alternator

14.4 mm 14.0 mm
Slip ring O.D. All models
0.567 in. 0.551 in.

Alternator

10.0 mm 8.5 mm
Brush length All models
0.3937 in. 0.3346 in.

Glow plug

Resistance All models Approx. 0.9

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TIGHTENING TORQUES
(1) Special Tightening Torques
For " * " marked screws, bolts and nuts on under table, apply engine oil to their threads and seats before tightening.
Cylinder head cover screw Injection pipe retaining nut Overflow pipe retaining nut

Z482-E2B Z482-E2B Z482-E2B

Z602-E2B Z602-E2B Z602-E2B
6.86 to 11.3 N m 24.5 to 34.3 N m 19.6 to 24.5 N m
D662-E2B D662-E2B D662-E2B
0.7 to 1.15 kgf m 2.5 to 3.5 kgf m 2.0 to 2.5 kgf m
D722-E2B D722-E2B D722-E2B
5.1 to 8.3 ft-lbs 18.1 to 25.3 ft-lbs 14.5 to 18.1 ft-lbs
D782-E2B D782-E2B D782-E2B
D902-E2B D902-E2B D902-E2B

Nozzle holder assembly Glow plug Rocker arm bracket screw

Z482-E2B Z482-E2B Z482-E2B

Z602-E2B Z602-E2B Z602-E2B
49.0 to 68.6 N m 7.85 to 14.7 N m 9.8 to 11.3 N m
D662-E2B D662-E2B D662-E2B
5.0 to 7.0 kgf m 0.8 to 1.5 kgf m 1.00 to 1.15 kgf m
D722-E2B D722-E2B D722-E2B
36.2 to 50.6 ft-lbs 5.8 to 10.8 ft-lbs 7.2 to 8.3 ft-lbs
D782-E2B D782-E2B D782-E2B
D902-E2B D902-E2B D902-E2B

Cylinder head screw Cylinder head tightening order

(A) 2 cylinder model (B) 3 cylinder model

f c j b g
j b g n f c k

i a h m e d l
e d i a h

Z482-E2B Z482-E2B
Z602-E2B Z602-E2B
37.3 to 42.2 N m (A) 2 cylinder model
D662-E2B D662-E2B a j
D722-E2B 3.8 to 4.3 kgf m D722-E2B (B) 3 cylinder model
27.5 to 31.1 ft-lbs a n
D782-E2B D782-E2B
D902-E2B D902-E2B

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Fan drive pulley screw Gear case screw Idle gear shaft mounting screw

Z482-E2B Z482-E2B Z482-E2B

Z602-E2B Z602-E2B Z602-E2B
98.1 to 107.9 N m 9.8 to 11.3 N m 9.8 to 11.3 N m
D662-E2B D662-E2B D662-E2B
10.0 to 11.0 kgf m 1.00 to 1.15 kgf m 1.00 to 1.15 kgf m
D722-E2B D722-E2B D722-E2B
72.3 to 79.6 ft-lbs 7.2 to 8.3 ft-lbs 7.2 to 8.3 ft-lbs
D782-E2B D782-E2B D782-E2B
D902-E2B D902-E2B D902-E2B

Camshaft set screw Fuel camshaft set screw & Connecting rod screw
Governor forklever set screw

Z482-E2B Z482-E2B Z482-E2B

Z602-E2B Z602-E2B Z602-E2B
D662-E2B 9.8 to 11.3 N m D662-E2B 9.8 to 11.3 N m D662-E2B 26.5 to 30.4 N m
1.00 to 1.15 kgf m 1.00 to 1.15 kgf m 2.7 to 3.1 kgf m
D722-E2B D722-E2B D722-E2B
7.2 to 8.3 ft-lbs 7.2 to 8.3 ft-lbs 19.5 to 22.4 ft-lbs
D782-E2B D782-E2B D782-E2B
D902-E2B D902-E2B D902-E2B

Flywheel screw Bearing case cover mounting screw Main bearing case screw 1

Z482-E2B Z482-E2B Z482-E2B

Z602-E2B Z602-E2B Z602-E2B
D662-E2B 53.9 to 58.8 N m D662-E2B 9.8 to 11.3 N m D662-E2B 12.7 to 15.7 N m
D722-E2B 5.5 to 6.0 kgf m D722-E2B 1.00 to 1.15 kgf m D722-E2B 1.3 to 1.6 kgf m
39.8 to 43.4 ft-lbs 7.2 to 8.3 ft-lbs 9.4 to 11.6 ft-lbs
D782-E2B D782-E2B D782-E2B
D902-E2B D902-E2B D902-E2B

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Main bearing case screw 2 Nozzle holder Oil pressure switch

Z482-E2B Z482-E2B Z482-E2B

Z602-E2B Z602-E2B Z602-E2B
26.5 to 30.4 N m 34.3 to 39.2 N m 14.7 to 19.6 N m
D662-E2B D662-E2B D662-E2B
2.7 to 3.1 kgf m 3.5 to 4.0 kgf m 1.5 to 2.0 kgf m
D722-E2B D722-E2B D722-E2B
19.5 to 22.4 ft-lbs 25.3 to 28.9 ft-lbs 10.8 to 14.5 ft-lbs
D782-E2B D782-E2B D782-E2B
D902-E2B D902-E2B D902-E2B

Starter (C terminal nut) Alternator pulley nut

Z482-E2B Z482-E2B
Z602-E2B Z602-E2B
D662-E2B 5.9 to 11.8 N m D662-E2B 58.3 to 78.9 N m
0.6 to 1.2 kgf m 5.95 to 8.05 kgf m
D722-E2B D722-E2B
4.3 to 8.7 ft-lbs 43.0 to 58.2 ft-lbs
D782-E2B D782-E2B
D902-E2B D902-E2B

(2) General Tightening Torques

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads.
Prior to tightening, be sure to check out the numbers as shown below.
None or 4 : Standard grade
7 : Special grade

Nominal Diameter Standard Grade Special Grade

7.9 to 9.3 N m 9.8 to 11.3 N m
M6 0.80 to 0.95 kgf m 1.00 to 1.15 kgf m
5.8 to 6.9 ft-lbs 7.23 to 8.32 ft-lbs

17.7 to 20.6 N m 23.5 to 27.5 N m

M8 1.8 to 2.1 kgf m 2.4 to 2.8 kgf m
13.0 to 15.2 ft-lbs 17.4 to 20.3 ft-lbs

39.2 to 45.1 N m 48.1 to 55.9 N m

M10 4.0 to 4.6 kgf m 4.9 to 5.7 kgf m
28.9 to 33.3 ft-lbs 35.4 to 41.2 ft-lbs

62.8 to 72.6 N m 77.5 to 90.2 N m

M12 6.4 to 7.4 kgf m 7.9 to 9.2 kgf m
46.3 to 53.5 ft-lbs 57.1 to 66.5 ft-lbs

KiSC issued 09, 2007 A