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    5l PDF

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    Samuel Zambrano
    This document provides specifications for an engine model, including dimensions for cylinders, pistons, crankshaft, camshaft, cylinder head, and torque values. It lists measurements and tolerances for components like piston clearance, bearing clearance, journal diameters, and head heights. It also includes information on ring gaps, valve dimensions, spring pressures, and sequences for tightening bolts.

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    5l PDF

    Uploaded by

    Samuel Zambrano
    458 views2 pages
    This document provides specifications for an engine model, including dimensions for cylinders, pistons, crankshaft, camshaft, cylinder head, and torque values. It lists measurements and tolerances for components like piston clearance, bearing clearance, journal diameters, and head heights. It also includes information on ring gaps, valve dimensions, spring pressures, and sequences for tightening bolts.

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    This document provides specifications for an engine model, including dimensions for cylinders, pistons, crankshaft, camshaft, cylinder head, and torque values. It lists measurements and tolerances for components like piston clearance, bearing clearance, journal diameters, and head heights. It also includes information on ring gaps, valve dimensions, spring pressures, and sequences for tightening bolts.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    458 views2 pages

    5l PDF

    Uploaded by

    Samuel Zambrano
    This document provides specifications for an engine model, including dimensions for cylinders, pistons, crankshaft, camshaft, cylinder head, and torque values. It lists measurements and tolerances for components like piston clearance, bearing clearance, journal diameters, and head heights. It also includes information on ring gaps, valve dimensions, spring pressures, and sequences for tightening bolts.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 2

    ENGINE SPECIFICATIONS

    January 2001 ES-TOY08R

    General

    Manufacturer TOYOTA
    Model/Year 5L 8/1997 -
    L/(CID) 2,986cc DIESEL No. of Cylinders 4
    Bore & Stroke 99.5mm X 96.0mm
    Firing Order 1342
    Compression Ratio 22.3 : 1 Idle Speed 750 - 850 rpm
    Comp. Pressure @ RPM 3.2 MPa @ 250 rpm 2.0 MPa min. <490 kPa diff.
    Oil Pressure 29 kPa min at idle Oil Capacity & Grade 6.5 ltr dry CD/E/F
    Injection Timing Dial indicator and plunger stroke.
    Block

    Bore Diameter Standard 99.500 99.530 mm


    Maximum Overbore 0.50 mm
    Liner Flange Height & Fit N/A Repair sleeves are available.
    Crankshaft Housing Bore 66.000 66.020 mm
    Camshaft Housing Bore No. 1: 38.015 38.027 mm Nos. 2 5: 31.015 31.027 mm
    Block Deck Height 0.20 mm warp limit
    Pistons & Rings

    Piston to Bore Clearance 0.04 0.06 mm @ 61.27 61.33 mm from crown.


    Piston Protrusion 0.68 0.97 mm (Graded head gaskets refer notes.)
    Gudgeon Pin Diameter 29.000 29.012 mm
    Gudgeon Pin Clearance 0.004 0.012 mm Limit: 0.05 mm
    Ring Equipment Top: 2.0 mm (K), 2nd: 1.5 mm; Oil: 4.0 mm.
    Piston Ring End Gap Top: 0.35 0.59 mm; 2nd: 0.47 0.72 mm; Oil: 0.20 0.52 mm.
    Ring to Groove Clearance Top: 0.057 0.101 mm; 2nd: 0.06 0.10 mm; Oil: 0.03 0.07 mm.
    Connecting Rods

    Big End Bore 58.004 58.024 mm


    Pin End Bore 32.000 32.030 mm
    Centre to Centre 147 mm
    Big End Width
    Bush ID Finished 29.008 29.020 mm
    Rod Side Clearance 0.080 0.300 mm Limit: 0.35 mm
    Bend/Twist 0.05 mm/100mm bend 0.15 mm/100 mm twist
    Camshaft

    Journal Diameters 1: 34.969 34.985 mm 2 5: 27.969 27.985 mm


    End Play 0.08 0.28 mm Limit: 0.35 mm
    Oil Clearance 0.022 0.074 mm Limit: 0.10 mm
    Minimum Lobe Height Inlet 54.30 mm Exhaust 55.00 mm Limit In 53.8 mm & Ex 54.5 mm
    Bend Limit 0.10 mm circle runout
    Crankshaft

    Main Journal Standard 61.985 62.000 mm


    Conrod Journal Standard 54.988 55.000 mm
    Harmonic Balancer Diam.
    Crank Gear Diameter
    Seal Diameter
    Thrust Thickness 2.430 2.480 mm
    Main Bearing Clearance 0.034 0.065 mm std. Limit: 0.10 mm
    Conrod Bearing Clearance 0.036 0.064 mm std. Limit: 0.10 mm
    Crankshaft End Play 0.040 0.250 mm Limit: 0.30 mm
    Journal Radius Main Conrod

    Cylinder Head

    Tappet Clearance Inlet 0.20 0.30 mm Cold Exhaust 0.40 0.50 mm Cold
    Head Height New Limit
    Warp Limit 0.2 mm
    Valve Seat Angle Inlet 45 Exhaust 45
    Valve Seat Width Inlet 1.5 1.9 mm Exhaust 1.8 2.2 mm
    Valve Head Margin Inlet 1.1 mm min. Exhaust 1.2 mm min.
    Valve Face Angle Inlet 44.5 Exhaust 44.5
    Valve Length Inlet 104.10 104.50 mm Exhaust 103.95 104.35 mm
    Valve Stem Diameter Inlet 7.975 7.990 mm Exhaust 7.960 7.975 mm
    Valve Guide Height Inlet 10.8 11.2 mm Exhaust 10.8 11.2 mm
    Valve Guide Clear. Std. Inlet 0.020 0.055 mm Exhaust 0.035 0.070 mm
    Valve Guide Clear. Limit Inlet 0.08 mm Exhaust 0.10 mm
    Valve Spring Pressure Type A 30.7 33.9 kg Type B 30.7 33.9 kg
    Valve Spring Free Length Type A 46.20 mm Type B 48.54 mm
    Valve Spring Install. Height Type A 37.0 mm Type B 37.0 mm
    Precom. Chamber Protrus. -0.03 - +0.03 mm
    Torque Specifications

    Main Bolts 10.5 kgf.m OILED


    Conrod Bolts 5.5 kgf.m + 90 OILED
    Head Bolts 8.0 kgf.m + 90 + 90 OILED
    Cam Cap Bolts 2.55 kgf.m OILED
    Manifold Bolts Inlet 2.4 kgf.m Exhaust 5.3 kgf.m
    Flywheel Bolts 12.5 kgf.m OILED
    Harmonic Balancer 24.0 kgf.m
    Torque Sequences

    17y 11x 9y 3x 1y 5x 7y 13x 15y 7 3 1 5 9

    16y 14y 8y 6y 2y 4y 10y 12y 18y 8 4 2 6 10


    Head Gasket Selection from Piston Protrusion
    X bolts 107 mm long Piston Protrusion Gasket Size
    Y bolts 127 mm long 0.68 0.77 mm Grade B 1.40 1.50 mm
    0.78 0.87 mm Grade D 1.50 1.60 mm
    0.88 0.97 mm Grade F 1.60 1.70 mm

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