Foton Series Light Bus. Service Manual — part 3

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

·24·

1.2.1.6 Cooling system

Cooling system is to radiate heat from excessive heat parts, so as to ensure a normal working temperature of

engine and avoid damage to its mechanical parts and other adverse influences.

BJ491EQ1 multi point electronic fuel injection gasoline engine adopts a forced water-cooling method.

The cooling system is mainly composed of cylinder block and water jacket in cylinder head, water pump, fan,

radiator, thermostat and silicon oil fan clutch etc.

1.2.1.7 Ignition system

Ignition system is to generate electric sparks to ignite the air-fuel mixture inside cylinder timely.

The ignition system is composed of battery, spark plug, ignition coil and high resistance cable.

1.2.1.8 Starting system

Starting system is to rotate crankshaft to a certain speed so as to suck combustible mixture into cylinder to

enable ignition and combustion.

The starting system is composed of starter, battery and other devices.

1.2.1.9 Electronic control fuel injection system

Through various sensors, electronic fuel injection system input signals of air intake volume, crankshaft

rotation / position and other auxiliary components to ECM. ECM processes these singals and commads auctators

to get uptimum air-fuel ratio and proper ignition timing, and ignite the combustible mixture to obtain an ideal

engine power performance, economical efficiency and emission index.

1.2.2 Specifications of gasoline engine

Description

BJ491EQ1

Type

4-stroke ，in-line,water cooling,wedge combustion chamber，

EFI

Number of Cylinders

4

Cylinder bore ［mm］

91

Piston stroke ［mm］

86

Displacement［L］

2.237

Rated output［kW/(r/min)］

76/4600~4600

Idle rpm ［r/min］

800±50

Max torque［N·m/(r/min)］

193/2000~2600

Fuel rate

RON93 or better ，non-leaded super gasoline

Min fuel consumption ［g/(kW·h)］

≤275

Oil rate

SF or better 10W/30or 15W/40，and 5W/30 in winter

Oil /fuel consumption rate ［%］

＜0.8

Average piston speed ［m/s］

13.19

Rotating direction of crankshaft

Counter- clockwise

Compression ratio

8.8：1

Anti-freezer

Ethylene anti-freezer

Oil volume (dry)［L］

4.2

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·25·

Description

BJ491EQ1

Coolant volume ［L］

7.9（With out worm pipe capacity）

Firing sequence

1-3-4-2

Intake open advance angle

12ºBTDC

Intake close delayed angle

48ºABDC

Exhaust open advance

54ºBBDC

Valve timing

Exhaust close delayed angle

10ºATDC

Coolant type

Forced cooling

Lubricating

Combine to use pressure and splash lubrication

Starting type

Electric starting

Net weight [kg]

145

Spark plug clearance[mm]

1.1±0.1

Max oil temperature [℃]

110

Coolant temperature [℃]

85~105（For high pressure cooling system ）

At idle

≥30

2000r/min

≥170

Oil pressure [kPa]

3000r/min

245~490

1.2.3 Specifications of gasoline engine main components

Description

Type

Specifications

ECM

ITMS-6F

491-FT01 for van；491-FT02 for pick-up；

491-FT03for SUV

O

2

sensor

25327985

Heat style

Spark plug

F6RTC or F5RTC

M14×1.25， 3~9kΩ resistance

Starter

QDY1253

U=12V，P=1kW

Alternator

U=14V，I=65A/90A

Fuel injector

25343351

Oil pump

Rotor type

Water pump

Centrifugal type

Thermostat

Valve opening temperature ；

76℃，

or more at 88℃，

valve

lift≥8mm

Oil pressure sensor

ZM10，Alarm pressure 39.2kPa

Oil filter

Paper element

Ignition coil

19005252

Clutch

Diaphragm spring type

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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1.2.4 The fitting clearance of main components

Description

Data

Warpage -- cylinder block side

0.15mm

Warpage -- manifold side

0.10mm

Intake

45º，75º

Refacing angle

Exhaust

45º

Connecting angle

45º

Culinder head

Valve seat

Connecting width

1.2~1.4mm

Inner diameter（mm）

8.010~8.030

STD（mm）

13.040~13.051

Valve guide

bushing

Outer dirmeter

O/S0.05（mm）

13.090~13.101

Intake

108.2

Overall length

STD（mm）

Exhaust

108.5

Intake

44.5º

Valve face angle

Exhaust

44.5º

Intake（mm）

7.970~7.985

Stem diameter

Exhaust（mm）

7.965~7.980

Intake

0.025~0.060

STD（mm）

Exhaust

0.030~0.065

Intake

0.10

Stem oil clearance

Limit （mm）

Exhaust

0.12

Intake

0.5

Valve stem end face

polishing limit（mm）

Exhaust

0.5

Intake

1.0～1.4

STD

Exhaust

1.3～1.7

Intake

0.5

Valve

Margin thickness

Limit（mm）

Limit

Exhaust

0.8

Free length （mm）

47

Installed tension at 40.6mm（N）

292~336

Valve spring

Squareness（mm）

Limit

2.0

STD

0.02~0.051

Rocker arm and

shaft

Oil clearance

（mm）

Limit

0.08

STD

0.017~0.056

Oil clearence

（mm）

Limit

0.10

Valve lifter and

lifter hole

Leak down test at196N

7~50s/1mm

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·27·

Description

Data

Manifold

Warpage

Limit（mm）

0.4

Chain slackness at 98N

Limit（mm）

13.5

Chain elongation

Limit（mm）

291.44

Cranshaft sprocket wear

Limit（mm）

59（Measure with chain）

Timing chain and

timing sprocket

Camshaft sprocket wear

Limit（mm）

114（Measure with

chain）

Tensioner head thickness

Limit（mm）

12.5

Chain tensioner

and vibration

damper

Damper thinckness

Limit（mm）

5

STD

0.07~0.22

Thrust clearance（mm）

Limit

0.3

STD

0.025~0.111

Camshaft

Journal oil clearance

（mm）

Limit

0.14

No.1

46.459~46.475

No.2

46.209~46.225

No.3

45.959~45.975

No.4

45.709~45.725

Journal diameter STD

（mm）

No.5

45.459~45.475

Out of round limit（mm） Limit

0.06

Intake

38.620~38.720

STD

Exhaust

38.629~38.729

Intake

38.26

Camshaft

Cam lobe height

（mm）

Limit

Exhaust

38.27

Top surface warpage（mm）

0.05

STD

91.00~91.03

Bore diameter（mm）

Limit

91.23

O/S 0.5（mm）

91.73

O/S0.75（mm）

91.98

Cylinder block

O/S1.00（mm）

92.23

STD

90.938~90.968

O/S 0.5（mm）

91.438~91.468

O/S0.75（mm）

91.688~91.718

Diameter of piston

（mm）

O/S1.00（mm）

91.938~91.968

Piston and piston

ring

Piston oil clearance（mm）

0.032~0.092

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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Description

Data

NO.1

0.27~0.39

NO.2

0.40~0.55

Oil side rail

0.20~0.70

Piston ring end gap

（mm）

Piston ring groove clearance

0.03~0.07

Thrust clearance（mm）

0.160~0.312

Benting per 100mm Limit

0.05

Connecting –rod

Twisting per100mm Limit

0.05

Flyweel

Runout （mm）

0.10

STD

0.02~0.20

Thrust clearence（mm）

Limit

0.35

STD

2.450~2.490

O/S0.125mm

2.565~2.615

Thrust washer

thickness

（mm）

O/S0.250mm

2.69~2.89

STD

0.020~0.051

Main jounral oil

clearence（mm）

limit

0.10

Main journal diameter

（mm）

STD

57.985~58.00

STD

0.020~0.051

Crank pin oil

clearence（mm）

Limit

0.10

Crank pin diameter （mm）

STD

47.985~48.00

Circle runout（mm）

Limit

0.06

Main journal taper and out –of round（mm）

Limit

0.02

Crankshft

Crank pin taper and out –of round（mm）

Limit

0.02

1.2.5 Tightening torque of main fasteners

1.2.5.1 Tightening torque for mechanical parts of gasoline engine

Parts

Tightening torque

（N.m）

Parts

Tightening torque

（N.m）

Rocker arm shaft×Cylinder head

25~32

Water pump ×cylinder block

39~48

M12

93~105

Cylinder head

bolts

M8

20~25

Chain case

20~25

Manifold ×cylinder head

49~55

Connecting cap ×rod

49~55

Spark plug ×cylinder head

25~30

Mainbearing cap × cylinder

block

78~88

Chain sprocket ×camshaft

90~100

Crankshaft pilley ×crankshaft

155~165

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·29·

Parts

Tightening torque

（N.m）

Parts

Tightening torque

（N.m）

Camshaft thrust washer ×cylinder

block

20~25

Flywheel×crankshaft

83~90

Water pump×chain case

20~25

Oil pan ×cylinder block

10~13

Oil pan drain plug

38~45

Head cover ×cylinder head

6~8

1.2.5.2 Tightening torque for EFI parts

NO

Parts

Tightening

torque（N.m）

NO

Parts

Tightening

torque（N.m）

1

Throttle body

10~15

5

Ignition coil

10~15

2

MAP sensor

7~12

6

O

2

sensor

38~46

3

Coolant temperature sensor

20~25

7

Upper and lower ports

20~25

4

Crankshaft

7~9

1.2.5.3 Tightening torque for other parts

NO

Parts

Tightening torque

（N.m）

NO

Parts

Tightening torque

（N.m）

1

M6

9~11

3

M10

41~591

2

M8

20~25

4

M12

73~

1.3 Technical specification of BJ486ZQ diesel engine

1.3.1 Technical specification of BJ486ZQ diesel engine

No

Description

Unit

Specifications

1

Type

4-stroke ,water cooling ,in line、DI

supercharging，diesel engine

2

Shape of combustion chamber

DI A type

3

Cylinder number

4

4

Cylinder bore

mm

86

5

Piston stroke

mm

100

6

Compression ratio

18

7

Diplacement

L

2.324

8

Firing sequence

1-3-4-2

9

Output /rpm

Kw/r/min

52/3300

10

Max torque /rpm

N．m/r/min

175/1900～2300

11

Min fuel consumption rate

G/kw/h

225

12

Adjustable velocity

%

≤10

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

·30·

No

Description

Unit

Specifications

13

Idle rpm

r/min

800～850

14

Smoke

m-1

≤1.8

15

Rotating directon of

crankshaft

Clockwise(see from front of diesel engine)

16

Method of lubrication

Pressure and splash

17

Starting method

Electric

18

Net weight

Kg

≤215

19

Overall dimensions

mm

754×592×671

1.3.2 Main technical parameters of BJ486ZQ diesel engine

Description

Parameters

Intake valve

Intake valve opens（before T.D.C） 8º,Intake valve closes(after

B.D.C)44º

Exhaust valve

Exhaust valve opens (before BDC) 44º ;

Exhaust valve closes (after TDC) 8º

Valve timing

Valve clearance

(cold)

Intake valve 0.35mm, Exhaust valve 0.35mm

Advance angle

8º～10ºCA(before T.D.C)

Exhaust gas temperature

≤550℃

Coolant outlet

temperature

≤95℃(use high pressure water tank ≤105℃)

Oil temperature

80℃～105℃

Idling oil pressure

≥0.07MPa

The range of

temperature and

pressure

Nominal speed oil

pressure

0.30～0.42MPa

Camshaft gear bolt

45～55

Main bearing cap bolt

160～180

Connecting –rod nut

55～65

Cylinder head bolt

170～190(bolt，Cylinder head)55～65(Small bolt，Cylinder

head)

Flywheel bolt

80～90

Tightening

torque(N.m)

Crankshaft pulley bolt

250～280

1.3.3 Main fitting specification of BJ486ZQ diesel engine

Description

Specifications

Type of oil pump

Gear type

Type of oil filter

Integral canister type

Lubrication system

Alarm oil pressure

80kPa

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·31·

Description

Specifications

Fuel filter

Rotor type

Fuel pump

Piston

Type of fuel injection

pump

BHF4P090213 type

Type of injector

“P”multi –hole type ，ZP20 type

Fuel supply sistem

Injector open pressure

22～23MPa

Water pump

Centrifugal type

Water pump flow

≥130L/min/4800r/min

Thermostat

Wax type

Cooling system

Fan

Silicon oil clutch and plastic fan

Glow plug relay

12V

Starter

12V,2.8kw

Alternator

14V,900W

Electronic sistem

Alternator rotating

direction

Clockwise (viewing from front)

Type

SJ44 or JP40S

Max rpm

18000r/min

Turbeocharger

Rated rpm

15000r/min

1.4 Technical specification of YC4F90-21 diesel engine

1.4.1 The technical specifications

NO

Description

Specifications

1

Engine type

4-stroke ，water cooling，in line，supercharging

2

Shape of combustion chamber

DI ω shape

3

Cylinder bore × Piston stroke （mm）

4-92×100

4

Displacement（L）

2.66

5

Compression ratio

17.5:1

6

Rated power/rpm kW（r/min）

65±5%/3400

7

Max torque /rpm （N.m/rpm）

210/1900~2200

8

Min fuel consumption〔g/（kW.h）

〕

≤215

9

（Oil/fuel ）consumption rate

≤0.2%

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

·32·

NO

Description

Specifications

10

Max rpm ( r/min)

≤3630

11

Min steady idle rpm

700~800

12

Firing order

1-3-4-2

13

Rotating direction of crankshaft

Clockwise（viewing from front of diesel engine）

14

Starting method

Electric

15

Starting performance

Startup at -10℃ w/o glow plug device, startup at-35℃ with

glow plug device; successful startup after 3 crankings

16

Smoke at free acceleration ( Rb)

≤2.0

17

Maximum smoke under full load

FSN

≤3.5

18

Noise (dB) (A)

≤116

19

Oil pan volume

7.5（L）

20

Oil temperature

90～115℃

Oil pressure at steady idling speed:>0.1MPa

21

Lubricating oil pressure

Working pressure: 0.3-0.6MPa

22

Coolant temperature

80～95℃

23

Exhaust gas temperature

≤650℃

24

Net weight（kg）

260（excl. clutch）

25

Overall dimensions
（L×W×H）mm

723.6×568.3×666

1.4.2 Main components specifications

NO

Description

Specifications

1

Type of fule injection pump

BHF4PL090

2

Type of injector

CKBAL63P967

3

Turbocharger

JP50

4

EGR controller (ECU)

Max environment temperature＜80℃

5

Transmission

connecting

plate

Fraction face of flywheel and clutch to transmission connecting plate :

52mm ; Input shaft bearinge end face to transmission connecting

plate : 25mm

6

Type of clutch

ф225 diaphragm spring clutch，ajusting height of clutch release lever:

36.4mm; Clutch is of involute spline type

7

Flywheel

108teeth，speed signal output from flywheel

8

Speed sensor

Mounting location aligns with flywheel gear ring center,

9

Input shaft bearing

6201 bearing，Input shaft front φ12mm

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·33·

NO

Description

Specifications

10

Oil pan volume

7.5L，Engine w/o oil from factory

11

Starting motor

DC reducer motor QDJ1303/3kW/12V

12

Generator

14V/90A，built-in voltage regulator

13

Air filter flow

≥600m

3

/h

14

Air filter resistance

≤2.5 kPa, with double stage elements

15

Air intake resistance –intake

system

≤4 kPa，Negative pressure alarm on air filter assembly

16

Radiating area -- radiator

≥16M

2

17

Expansion tank

≥15% of total cooling system volume

18

Fuel filter flow

≥0.7L/min，particles after filter＜0.005mm

19

Cleanness of front fuel tank

to fuel pump inlet pipe

＜10mg

20

Cleanness from air filter to

engine intake manifold

＜10mg

21

Catalytic converter

Clear with compressed air after every 10000km

22

Battery V /Capacity

12V/80Ah

23

Engine oil

Should be higher than APL CF-4 rate according to environment

temperature

24

Injection pump & oil

5W/30，CF rate diesel engine oil

25

Fuel

Choose fuel according to environment temperature

1.5 Model 2RZ-E Engine Technical specification

1.5.1 Technical specification

Model

2RZ - E

Type

In line, four cylinders, four strokes, water-cooling,

multi-point EFI

No. of cylinder

4

Cylinder bore (mm)

95

Piston stroke (mm)

86

Total displacement (L)

2.438

Rated power / Rpm

85KW/5000rpm

Min. idle stablized Rpm

800 ±50 rpm

DP Rpm

2000 rpm

Max torque / Rpm

193N.m / 2600rpm

Fuel rating

95# or above unlead fuel (GB17930)

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

·34·

Model

2RZ - E

Oil rating

SF 10W/30 or 15W/40 (GB11121)

Crankshaft turing direction (viewing from flywheel end

to gasoline engine front end)

Counter-clockwise

Compression ratio

9

Igniting sequence

1-3-4-2

Cooling

Forced water-cooling

Lubrication

Pressure and splashing

Starting

Power startup

1.5.2 Main component specification

Description

Type

Specification

EFI system

Toyota computer control system

(TCCS)

Spark plug

P16R：BPR5EP11

Starter

U=12V P=1.4Kw

Alternator

U=13.9～15.1V, I=60A

Distributor （mm）

( type 11 A)

Singnal generator clearance: 0.2～0.4

Signal generator (sensing

coil ) resistance（Ω）

280～360

Ignition coil

U=12V primary coil resistance 0.4～0.5Ω;

secondary coil resistance 10.0～14.0 KΩ

Oil pump

Rotary

Water pump

Centrifugal

Thermostat

Wax type, valve opening temperature 80～

84°C, 95℃fully open travel ≥ 8mm

Oil filter

Fully flow type with limit valve, spin-on

type with paper element

Clutch

Diaphragm spring type

1.5.3 Parameters for check and adjustment

Intake valve

0.2～0.3

Valve clearance (cool engine)（mm）

Exhaust valve

0.25～0.35

Ignition advance angle

5°BTDC (at 800rpm)

Ignition sequence

1-3-4-2

Primary coil resistance（Ω）

0.4～0.5

Secondary coil resistance（KΩ）

10.0～14.0

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·35·

Distributor signal generator (sensing

coil ) resistance（Ω）

280～360

Compress pressure（KPa）

1226

Min. pressure（KPa）

883

Compress pressure difference among

cylinders（KPa）

98

Intake pipe vacuum (at idle)（KPa） Larger than 53.3

Pollutant emission at idle

CO ≤0.5%

Spark plug clearance（mm）

1.1

Idle (800rpm)

29.4KPa

Oil pressure

Mid-high rpm (3000rpm)

245～490KPa

Oil temperature

≤110℃

Oil volume ( fill at dry)

5.2L

(oil filter contains oil)

3.6

Refill after draining （L）

(oil filter contains no oil)

4.1

Fan belt tension (pressure 10kg, the

deflection under 98 N)

New belt: 5～7mm

Used belt: 7～8 mm

Coolant volume (use softened water

or antifreezer) without heater

8L

With front heater

9L

With front and rear heater

10L

Standard

74～103

Radiator Relieve valve opening

pressure（KPa）

Limit

59

Battery fluid gravity under 20°C

1．25～1．27

Rated output current

60 A

Rotor coil resistance

2.8～3.0Ω

Standard

10.5

Brush exposed length（mm）

Limit

1.5

Standard

14.2～14.4

Alternator

Sliding ring diameter（mm）

Limit

12.8

At 25℃

13.9～15.1V

Alternator regulator

Regulator Voltage

At 115℃

13.5～14.3V

Rated voltage and output power

12V, 1.4Kw

Amp

90 A or less at 11.5V

Idle property

Rpm

3000 rpm or more

Standard

15.5

Brush length（mm）

Limit

8.5

Starter motor

Spring mounting load

Standard

18～24N

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

·36·

Standard

0.100～0.175

Pump body clearance（mm）

Limit

0.30

Standard

0.11～0.24

Side clearance（mm）

Limit

0.35

Standard

0.03～0.09

Oil pump

Radial clearance（mm）

Limit

0.15

Fuel pressure

2.7～3.1 bar

1.5.4 Fitting sizes of main parts

Description

Data

Warpage (contacting face with block)（mm）

Limit

0.15

Warpage (contacting face with intake /

exhaust manifolds)（mm）

Limit

0.20

Intake valve seat

30°45°60°

Cone angle

Exhaust valve seat

30°45°60°

Contacting angle

45°

Cylinder head

Valve

seat

Contacting width（mm）

1.2～1.6

Inner diameter（mm）

8.01～8.03

Standard（mm）

13.040～13.051

Outer

diameter

Enlarge 0.05mm（mm）

13.090～13.091

Valve guide

Projecting height（mm）

18.2～18.6

Intake valve

102.00

Valve length（mm）

Standard

Exhaust valve

102.25

Intake valve

44.5°

Valve cone angle

Exhaust valve

44.5°

Intake valve

7.970～7.985

Valve stem diameter
（mm）

Exhaust valve

7.965～7.980

Intake valve

0.025～0.06

Standard

Exhaust valve

0.030～0.065

Intake valve

0.08

Valve stem clearance
（mm）

Limit

Exhaust valve

0.10

Intake valve

0.5

Valve stem end face

grinding limit（mm）

Exhaust valve

0.5

Intake valve

0.5

Valve

Valve

top

edge

thickness limit（mm）

Exhaust valve

0.8

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·37·

Description（mm）

Data

Free length（mm）

47.31

Mounting tension（N）

238～265

Valve spring

Un-verticality （mm）

2.0

Sealing face warpage—intake（mm）

Limit

0.2

Intake/exhaust

manifolds

Sealing face warpage—exhaust （mm）

Limit

0.7

16 links chain length（mm）

Limit

146.6

Allowable wear on crankshaft sprocket diameter（mm）

Limit

59.4

Timing chain

and sprocket

Allowable wear on camshaft sprocket diameter（mm）

Limit

113.8

Wear of damper plate（mm）

Limit

1.0

Damper plate

and

sliding

plate

Wear of sliding plate （mm）

Limit

1.0

Standard

0.08～0.18

Axial clearance（mm）

Limit

0.25

Standard

0.025～0.066

Radial clearance（mm）

Limit

0.10

Shaft journal diameter（mm）

Standard

33.959～33.975

Center shaft journal runout （mm）

Limit

0.06

Camshaft

Cam lub height（mm）

Standard

47.84～47.94

Top plane warpage（mm）

Limit

0.05

Cylinder bore（mm）

Limit

94.99～95.00

Fit with piston of standard size, allowable bore wear（mm）

95.06

Fit with enlarged (0.5mm) piston, allowable bore wear （mm）

95.56

Taper and out of round（mm）

Limit

0.01

Standard No1

64.000～64.008

No 2

64.009～64.016

Main bearing hole on cylinder block（mm）

No 3

64.017～84.024

Cylinder

block

Main bearing hole diameter at the main bearing inner hole

reduction(0.25mm) non-grouping （mm）

64.000～64.024

Description

Data (mm)

Standard

94.95～94.96

Piston

diameter

（mm）

Enlarge 0.50mm

95.45～95.46

Clearance between piston and cylinder（mm）

0.03～0.05

Standard

0.22～0.35

Piton and ring

Piston ring open clearance
（mm）

Top ring

Limit

0.95

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

·38·

Description

Data (mm)

Standard

0.03～0.43

Second ring

Limit

1.03

Standard

0.45～0.60

Oil ring

Limit

1.2

Standard

0.03～0.08

Side clearance between ring

groove and ring（mm）

Limit

0.2

Piton and ring

Piston pin mounting temperature

80°C

Standard

0.160～0.312

Connecting rod axial clearance
（mm）

Limit

0.35

Standard No1

56.000～56.008

Standard No2

56.009～56.016

Inner diameter -- connecting

rod big end（mm）

Standard No3

56.017～56.024

Connecting rod big end inner diameter at bearing inner hole

reduction (0.25mm), non-grouping（mm）

56.000～56.024

Standard No1

1.481～1.485

Standard No2

1.486～1.489

Center wall thickness -- connecting rod bearing
（mm）

Standard No3

1.490～1.493

Center wall thickness at bearing inner hole reduction (0.25mm),

non-grouping（mm）

1.601～1.607

Standard

0.030～0.059

Bearing clearance（mm）

Limit

0.1

Standard

0.005～0.011

Clearance between piston pin and bushing

（mm）

Limit

0.015

Piston pin diameter（mm）

Standard

24.000～24.009

Bushing inner diameter（mm）

24.008～24.017

Bending & distortion at each 100mm（mm）

Limit

0.05

Connecting rod and

bearing

Twisting at each 100mm（mm）

Limit

0.15

Flywheel

End face run-out （mm）

Limit

0.1

Standard

0.02～0.022

Axial clearance （mm）

Limit

0.3

Thrust plate thickness（mm）

Standard

2.400～2.440

Standard

0.020～0.049

Crankshaft

Main journal radial clearance（mm）

Limit

0.1

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·39·

Description

Data (mm)

Main journal diameter（mm）

59.987～60.000

Main journal min. diameter（mm）

59.745～59.755

Standard No1

1.986～1.990

Standard No2

1.991～1.994

Standard No3

1.995～1.998

Main bearing center wall thickness（mm）

Center

wall

thickness

at

main bearing

inner

hole

reduction

(0.25),

non-grouping

1.601～1.607

Crank pin diameter（mm）

Standard

52.987～53.000

Crank pin min. diameter (at connecting rod

bearing reduction of 0.25mm)（mm）

52.745～52.755

Run-out （mm）

Limit

0.03

Taper and out of round –main journal（mm）

Limit

0.005

Crankshaft

Taper and out of round—crank pin journal
（mm）

Limit

0.005

Outer diameter（mm）

Standard

37.922～37.932

Standard

0.028～0.053

Valve tappet

Clearance （mm）

Limit

0.1

1.5.5 The specification of tightening torque

1.5.5.1 Tightening torque of main fastener

Tightened parts

N-m

Cylinder head x camshaft bearing cap

16

Cylinder head x chain tensioner

21

Cylinder head x spark plug

18

Cylinder head x exhaust manifold

49

Cylinder head x fuel pump

20

Nut

12

Cylinder block x oil filter bracket

Joint bolt

67

Cylinder block x water plug

25