2ZR-FE ENGINE MECHANICAL SERVICE DATA

V-ribbed belt Deflection 98 N (10 kgf, 22.0 lbf)
Specified Condition 12 to 13 mm (0.47 to 0.51 in.)
Engine idle speed Standard 770 to 870 rpm
Compression pressure Standard

1373 kPa (14.0 kgf/cm2, 199 psi)
Minimum pressure

1079 kPa (11.0 kgf/cm2, 157 psi)
Difference between each cylinder

98 kPa (1.0 kgf/cm2, 14.2 psi)
Oil pump drive gear (with chain) Minimum 48.2 mm (1.898 in.)
Oil pump drive shaft gear (with chain) Minimum 48.2 mm (1.898 in.)
Crankshaft timing sprocket (with chain) Minimum 51.1 mm (2.012 in.)
Camshaft timing gear assembly (with chain) Minimum 96.8 mm (3.811 in.)
Camshaft timing exhaust gear assembly (with chain) Minimum 96.8 mm (3.811 in.)
Chain tensioner slipper wear Maximum 1.0 mm (0.0394 in.)
No. 1 chain vibration damper wear Maximum 1.0 mm (0.0394 in.)
No. 2 chain vibration damper wear Maximum 1.0 mm (0.0394 in.)
Chain tensioner plate wear Maximum 1.0 mm (0.0394 in.)
Cylinder head set bolt length Standard 146.8 to 148.2 mm (5.7795 to 5.8346 in.)
Maximum 149.2 mm (5.874 in.)
Cylinder head set bolt outside diameter Standard 9.77 to 9.96 mm (0.3846 to 0.3921 in.)
Minimum 9.4 mm (0.3701 in.)
Ring pin (Stiffening crankcase assembly) Protrusion 3 mm (0.118 in.)
No. 1 camshaft bearing Dimension A-B 0.7 mm (0.0276 in.) or less
No. 2 camshaft bearing Dimension A 1.05 to 1.75 mm (0.0413 to 0.0689 in.)
Chain sub-assembly elongation Maximum 115.2 mm (4.535 in.)
No. 2 Chain sub-assembly elongation Maximum 102.1 mm (4.019 in.)
Camshaft circle runout Maximum 0.04 mm (0.00157 in.)
Camshaft cam lobe height Standard 42.816 to 42.916 mm (1.6857 to 1.6896 in.)
Minimum 42.666 mm (1.6798 in.)
Camshaft journal diameter No. 1 Standard 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other Standard 22.949 to 22.965 mm (0.90350 to 0.90413 in.)
Camshaft thrust clearance Standard 0.06 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum 0.17 mm (0.00669 in.)
Camshaft oil clearance No. 1 journal Standard 0.030 to 0.063 mm (0.00118 to 0.00248 in.)
Maximum 0.085 mm (0.00335 in.)
Other journals Standard 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum 0.09 mm (0.00354 in.)
No. 2 camshaft circle runout Maximum 0.04 mm (0.00157 in.)
No. 2 camshaft cam lobe height Standard 44.336 to 44.436 mm (1.7455 to 1.7494 in.)
Minimum 44.186 mm (1.7396 in.)
No. 2 camshaft diameter No. 1 journal Standard 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other journal Standard 22.949 to 22.965 mm (0.90350 to 0.90413 in.)
No. 2 camshaft thrust clearance Standard 0.06 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum 0.17 mm (0.00669 in.)
No. 2 camshaft oil clearance No. 1 journal Standard 0.030 to 0.063 mm (0.00118 to 0.00248 in.)
Maximum 0.085 mm (0.00335 in.)
Other journals Standard 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum 0.09 mm (0.00354 in.)
Exhaust manifold warpage Maximum 0.7 mm (0.028 in.)
Cylinder head
Cylinder head warpage Cylinder block side Maximum 0.05 mm (0.00197 in.)
Intake manifold side Maximum 0.10 mm (0.00394 in.)
Exhaust manifold side Maximum 0.10 mm (0.00394 in.)
Compression spring Standard free length 51.88 mm (2.042 in.) or 51.90 mm (2.043 in.)
Maximum deviation 1.3 mm (0.0512 in.)
Intake valve Overall length Standard 109.34 mm (4.3047 in.)
Minimum 108.84 mm (4.2850 in.)
Valve stem diameter Standard 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.5 mm (0.0197 in.)
Valve seat width Standard 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust valve Overall length Standard 108.25 mm (4.2618 in.)
Minimum 107.75 mm (4.2421 in.)
Valve stem diameter Standard 5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Margin thickness Standard 1.01 mm (0.0398 in.)
Minimum 0.5 mm (0.0197 in.)
Valve seat width Standard 1.0 to 1.4 mm (0.0394 to 0.0551 in)
Intake valve guide bush Inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.080 mm (0.00315 in.)
Protrusion height Standard 9.9 to 10.3 mm (0.3898 to 0.4055 in.)
Intake valve guide bush bore diameter - Standard 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
New guide bush selection chart STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Exhaust valve guide bush Inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.085 mm (0.00335 in.)
Protrusion height Standard 11.15 to 11.55 mm (0.4390 to 0.4547 in.)
Exhaust valve guide bush bore diameter - Standard 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
New guide bush selection chart STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Ring pin protrusion height (Cylinder head cover sub-assembly) Standard 6.5 to 7.5 mm (0.256 to 0.295 in.)
Spark plug tube Protrusion height Standard 122 mm (4.80 in.)
Connecting rod
Connecting rod thrust clearance Standard 0.160 to 0.342 mm (0.00630 to 0.0135 in.)
Maximum 0.342 mm (0.0135 in.)
Connecting rod oil clearance Crankshaft side Standard 0.014 to 0.038 mm (0.000551 to 0.00150 in.)
Maximum 0.070 mm (0.00276 in.)
Piston side Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.014 mm (0.000551 in.)
Connecting rod bearing thickness Mark 1 Standard 1.489 to 1.493 mm (0.058621 to 0.058779 in.)
Mark 2 Standard 1.494 to 1.497 mm (0.058819 to 0.058937 in.)
Mark 3 Standard 1.498 to 1.501 mm (0.058976 to 0.059094 in.)
Connecting rod bearing dimension (A-B) 0.7 mm (0.0276 in.) or less
Connecting rod small end bore diameter Standard 20.012 to 20.021 mm (0.7879 to 0.7882 in.)
Connecting rod small end bore diameter (Reference) Mark A Standard 20.012 to 20.015 mm (0.78787 to 0.78799 in.)
Mark B Standard 20.016 to 20.018 mm (0.78803 to 0.78811 in.)
Mark C Standard 20.019 to 20.021 mm (0.78815 to 0.78823 in.)
Connecting rod large end bore diameter (Resistance) Mark 1 Standard 47.000 to 47.008 mm (1.85039 to 1.85070 in.)
Mark 2 Standard 47.009 to 47.016 mm (1.85074 to 1.85102 in.)
Mark 3 Standard 47.017 to 47.024 mm (1.85106 to 1.85133 in.)
Crankshaft pin diameter Standard 43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Connecting rod misalignment. Maximum 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
Connecting rod twist Maximum 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Cylinder block sub-assembly Warpage Maximum 0.05 mm (0.00197 in.)
Cylinder bore diameter Standard 80.500 to 80.513 mm (3.1693 to 3.1698 in.)
Maximum 80.633 mm (3.1745 in.)
Ring pin (Cylinder block sub-assembly) Protrusion height Standard 7.5 to 8.5 mm (0.295 to 0.335 in.)
Straight pin protrusion height Pin A Standard 18.5 to 19.5 mm (0.728 to 0.768 in.)
Pin B Standard 5.0 to 7.0 mm (0.197 to 0.276 in.)
Pin C Standard 11 to 13 mm (0.433 to 0.512 in.)
Pin D Standard 8.0 to 10 mm (0.315 to 0.394 in.)
Pin E Standard 5.0 to 6.0 mm (0.197 to 0.236 in.)
Piston
Piston diameter Standard 80.471 to 80.491 mm (3.16814 to 3.16893 in.)
Piston oil clearance Standard 0.009 to 0.042 mm (0.000354 to 0.00165 in.)
Maximum 0.08 mm (0.00315 in.)
Piston pin bore diameter Standard 20.006 to 20.015 mm (0.7876 to 0.7880 in.)
Piston pin bore diameter (Reference) Mark A Standard 20.006 to 20.009 mm (0.78764 to 0.78775 in.)
Mark B Standard 20.010 to 20.012 mm (0.78779 to 0.78787 in.)
Mark C Standard 20.013 to 20.015 mm (0.78791 to 0.78799 in.)
Piston ring
Piston ring groove clearance No. 1 Ring Standard 0.02 to 0.07 mm (0.000787 to 0.00276 in.)
No. 2 Ring Standard 0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Oil Ring Standard 0.07 to 0.13 mm (0.00276 to 0.00512 in.)
Piston ring end gap No. 1 Ring Standard 0.20 to 0.30 mm (0.00787 to 0.0118 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 Ring Standard 0.30 to 0.50 mm (0.0118 to 0.0197 in.)
Maximum 0.70 mm (0.0276 in.)
Oil Ring Standard 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum 0.70 mm (0.0276 in.)
Piston pin
Piston pin diameter Standard 20.004 to 20.013 mm (0.7876 to 0.7879 in.)
Piston pin diameter (Resistance) Mark A Standard 20.004 to 20.007 mm (0.78756 to 0.78768 in.)
Mark B Standard 20.008 to 20.010 mm (0.78771 to 0.78779 in.)
Mark C Standard 20.011 to 20.013 mm (0.78783 to 0.78791 in.)
Piston pin oil clearance Standard -0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)
Maximum 0.008 mm (0.000315 in.)
Connecting rod bolt diameter Standard 6.6 to 6.7 mm (0.2598 to 0.2638 in.)
Minimum 6.4 mm (0.2520 in.)
Crankshaft
Crankshaft thrust clearance Standard 0.04 to 0.14 mm (0.00157 to 0.00551 in.)
Maximum 0.18 mm (0.00709 in.)
Thrust washer thickness Standard 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Cylinder block main journal bore diameter (Reference) Mark 0 Standard 52.000 to 52.002 mm (2.04724 to 2.04732 in.)
Mark 1 Standard 52.003 to 52.004 mm (2.04736 to 2.04740 in.)
Mark 2 Standard 52.005 to 52.006 mm (2.04744 to 2.04748 in.)
Mark 3 Standard 52.007 to 52.009 mm (2.04752 to 2.04759 in.)
Mark 4 Standard 52.010 to 52.011 mm (2.04763 to 2.04767 in.)
Mark 5 Standard 52.012 to 52.013 mm (2.04771 to 2.04775 in.)
Mark 6 Standard 52.014 to 52.016 mm (2.04779 to 2.04787 in.)
Main journal diameter Standard 47.988 to 48.000 mm (1.8893 to 1.8898 in.)
Taper and distortion Maximum 0.004 mm (0.000157 in.)
Main journal diameter (Reference) Mark 0 Standard 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
Mark 1 Standard 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
Mark 2 Standard 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
Mark 3 Standard 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
Mark 4 Standard 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
Mark 5 Standard 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Crankshaft journal diameter (Reference) Mark 0 Standard 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
Mark 1 Standard 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
Mark 2 Standard 47.995 to 47.996 mm (1.88956 to 1.88961 in.)
Mark 3 Standard 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
Mark 4 Standard 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
Mark 5 Standard 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Main bearing center wall thickness (Reference) Mark 1 Standard 1.994 to 1.997 mm (0.07850 to 0.07862 in.)
Mark 2 Standard 1.998 to 2.000 mm (0.07866 to 0.07874 in.)
Mark 3 Standard 2.001 to 2.003 mm (0.07878 to 0.07886 in.)
Mark 4 Standard 2.004 to 2.006 mm (0.07890 to 0.07898 in.)
Circle runout Maximum 0.03 mm (0.00118 in.)
Oil clearance Standard 0.016 to 0.039 mm (0.000630 to 0.00154 in.)
Maximum 0.050 mm (0.00197 in.)
Crank pin diameter Standard 43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Taper and distortion Maximum 0.004 mm (0.000157 in.)
Crankshaft bearing cap set bolt length Standard 84.3 to 85.7 mm (3.3189 to 3.3740 in.)
Minimum 86.7 mm (3.4134 in.)
Crankshaft bearing cap set bolt diameter Standard 9.77 to 9.96 mm (0.3846 to 0.3921 in.)
Minimum 9.1 mm (0.3583 in.)
Crankshaft bearing Dimension A Standard 0.5 to 1.0 mm (0.0197 to 0.0394 in.)
Dimension A-B Standard 0.5 mm (0.0197 in.) or less
No. 1 ventilation case seal diameter Standard 2.0 to 3.0 mm (0.0787 to 0.118 in.)
Camshaft housing seal diameter Standard 3.5 to 4.5 mm (0.138 to 0.177 in.)