2AR-FSE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminals TC and CG of DLC3 connected 8 to 12° BTDC at idle (Transmission in park)
Terminals TC and CG of DLC3 disconnected 5 to 20° BTDC at idle (Transmission in park)
Idle speed 950 to 1050 rpm (Transmission in park)
Compression Compression pressure

1100 kPa (11.2 kgf/cm2, 160 psi) or higher
Minimum pressure

900 kPa (9.2 kgf/cm2, 131 psi)
Difference between each cylinder

100 kPa (1.0 kgf/cm2, 15 psi) or less
ENGINE UNIT
Camshaft Circuit runout Maximum 0.03 mm (0.00118 in.)
Journal diameter No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.)
Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.)
No. 2 camshaft Circuit runout Maximum 0.03 mm (0.00118 in.)
Journal diameter No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.)
Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.)
Cam lobe height Standard for intake 44.183 to 44.283 mm (1.739 to1.743 in.)
for exhaust 43.533 to 43.633 mm (1.714 to1.718 in.)
for fuel pump drive 40.554 to 40.654 mm (1.597 to1.601 in.)
Maximum for intake 44.073 mm (1.735 in.)
for exhaust 43.423 mm (1.710 in.)
for fuel pump drive 40.554 mm (1.597 in.)
Camshaft timing gear assembly Minimum diameter (with chain sub-assembly) 115.12 mm (4.53 in.)
Camshaft timing exhaust gear assembly Minimum diameter (with chain sub-assembly) 115.12 mm (4.53 in.)
Chain sub-assembly Maximum chain elongation 137.7 mm (5.42 in.)
Crankshaft timing gear or sprocket Minimum sprocket diameter (with chain sub-assembly) 59.94 mm (2.36 in.)
Chain tensioner slipper Maximum depth 1.0 mm (0.0394 in.)
No. 1 chain vibration damper Maximum depth 1.0 mm (0.0394 in.)
Timing chain guide Maximum depth 1.0 mm (0.0394 in.)
No. 1 balance shaft Thrust clearance Standard 0.07 to 0.11 mm (0.00276 to 0.00433 in.)
Maximum 0.11 mm (0.00433 in.)
No. 2 balance shaft Thrust clearance Standard 0.07 to 0.11 mm (0.00276 to 0.00433 in.)
Maximum 0.11 mm (0.00433 in.)
Balance shaft Backlash Standard 0.04 to 0.16 mm (0.00157 to 0.00630 in.)
Maximum 0.16 mm (0.00630 in.)
Cylinder head set bolt Diameter Standard 10.85 to 11.00 mm (0.427 to 0.433 in.)
Maximum 10.6 mm (0.417 in.)
Camshaft oil clearance Standard Intake No. 1 journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Exhaust No. 1 journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.)
Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum Intake No. 1 journal 0.085 mm (0.00335 in.)
Exhaust No. 1 journal 0.095 mm (0.00374 in.)
Other journal 0.085 mm (0.00335 in.)
Ring pin Standard Protrusion Height Stiffening crankcase assembly lower side 4.3 to 5.3 mm (0.169 to 0.209 in.)
Camshaft housing sub-assembly lower side 2.7 to 3.3 mm (0.106 to 0.130 in.)
CYLINDER HEAD
Cylinder head sub-assembly Maximum Warpage Cylinder Block Sub-assembly Side 0.05 mm (0.00197 in.)
Intake Side 0.10 mm (0.00394 in.)
Exhaust Side 0.10 mm (0.00394 in.)
Inner compression spring Standard free length 47.38 mm (1.87 in.)
Maximum deviation 1.05 mm (0.0413 in.)
Intake valve Valve stem diameter 5.470 to 5.485 mm (0.215 to 0.216 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.5 mm (0.0197 in.)
Overall length Standard 103.92 mm (4.09 in.)
Minimum 103.42 mm (4.07 in.)
Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.215 to 0.216 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.5 mm (0.0197 in.)
Overall length Standard 112.91 mm (4.45 in.)
Minimum 112.41 mm (4.43 in.)
Valve guide bush Bush inside diameter 5.510 to 5.530 mm (0.217 to 0.218 in.)
Standard oil clearance Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum Oil Clearance Intake 0.08 mm (0.00315 in.)
Exhaust 0.10 mm (0.00394 in.)
Bush bore diameter (Cylinder head sub-assembly side) 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Bush bore diameter (Valve guide bush) 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.)
Standard protrusion height Intake 14.85 to 15.10 mm (0.585 to 0.595 in.)
Exhaust 14.25 to 14.50 mm (0.561 to 0.571 in.)
Spark plug tube Standard protrusion height 112 mm (4.41 in.)
Intake valve seat Standard width 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust valve seat Standard width 1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Ring pin Standard protrusion height 6.5 to 7.5 mm (0.256 to 0.295 in.)
Camshaft thrust clearance Standard 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum 0.170 mm (0.00669 in.)
CYLINDER BLOCK
Connecting rod sub-assembly Thrust clearance Standard 0.160 to 0.512 mm (0.00630 to 0.0202 in.)
Maximum 0.512 mm (0.0202 in.)
Oil clearance Standard 0.030 to 0.063 mm (0.00118 to 0.00248 in.)
Maximum 0.07 mm (0.00276 in.)
Diameter Mark 1 54.500 to 54.508 mm (2.14567 to 2.14598 in.)
Mark 2 54.509 to 54.516 mm (2.14602 to 2.14629 in.)
Mark 3 54.517 to 54.524 mm (2.14633 to 2.14661 in.)
Standard connecting rod small end bush inside diameter Mark A 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
Mark B 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
Mark C 22.012 to 22.014 mm (0.86661 to 0.86669 in.)
Maximum bend 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Connecting rod bearing Center wall thickness Mark 1 1.483 to 1.487 mm (0.05839 to 0.05854 in.)
Mark 2 1.488 to 1.491 mm (0.05858 to 0.05870 in.)
Mark 3 1.492 to 1.495 mm (0.05874 to 0.05886 in.)
Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)
Crankshaft Thrust clearance Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Maximum 0.30 mm (0.0118 in.)
Maximum circle runout 0.03 mm (0.00118 in.)
Standard diameter Main journal 54.988 to 55.000 mm (2.1649 to 2.1654 in.)
Crank pin 51.492 to 51.500 mm (2.027 to 2.028 in.)
Maximum taper and out-of-round Main journal 0.003 mm (0.000118 in.)
Crank pin 0.003 mm (0.000118 in.)
Oil clearance Standard 0.017 to 0.040 mm (0.000669 to 0.00157 in.)
Maximum 0.05 mm (0.00197 in.)
Standard crankshaft main journal diameter (B) Mark 0 54.999 to 55.000 mm (2.16531 to 2.16535 in.)
Mark 1 54.997 to 54.998 mm (2.16523 to 2.16527 in.)
Mark 2 54.995 to 54.996 mm (2.16515 to 2.16519 in.)
Mark 3 54.993 to 54.994 mm (2.16507 to 2.16511 in.)
Mark 4 54.991 to 54.992 mm (2.16500 to 2.16504 in.)
Mark 5 54.988 to 54.990 mm (2.16488 to 2.16496 in.)
Crankshaft bearing Standard center wall thickness Mark 1 (Silver) 1.991 to 1.994 mm (0.07839 to 0.07850 in.)
Mark 1 (Black) 1.992 to 1.995 mm (0.07843 to 0.07854 in.)
Mark 2 (Silver) 1.995 to 1.997 mm (0.07854 to 0.07862 in.)
Mark 2 (Black) 1.996 to 1.998 mm (0.07858 to 0.07866 in.)
Mark 3 (Silver) 1.998 to 2.000 mm (0.07866 to 0.07874 in.)
Mark 3 (Black) 1.999 to 2.001 mm (0.07870 to 0.07878 in.)
Mark 4 (Silver) 2.001 to 2.003 mm (0.07878 to 0.07886 in.)
Mark 4 (Black) 2.002 to 2.004 mm (0.07882 to 0.07890 in.)
Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)
Upper crankshaft thrust washer Standard thickness 1.93 to 1.98 mm (0.0760 to 0.0780 in.)
Cylinder block assembly Maximum warpage 0.05 mm (0.00197 in.)
Cylinder bore diameter Reference value (New Parts) 90.000 to 90.013 mm (3.543 to 3.544 in.)
Maximum diameter 90.13 mm (3.55 in.)
Standard journal inside diameter (A) Mark 0 59.000 to 59.002 mm (2.32283 to 2.32291 in.)
Mark 1 59.003 to 59.004 mm (2.32295 to 2.32299 in.)
Mark 2 59.005 to 59.006 mm (2.32303 to 2.32307 in.)
Mark 3 59.007 to 59.009 mm (2.32311 to 2.32318 in.)
Mark 4 59.010 to 59.011 mm (2.32322 to 2.32326 in.)
Mark 5 59.012 to 59.013 mm (2.32330 to 2.32334 in.)
Mark 6 59.014 to 59.016 mm (2.32338 to 2.32346 in.)
Piston Diameter Reference value (New Parts) 89.986 to 89.996 mm (3.5428 to 3.5431in.)
Oil clearance Reference value (New Parts) 0.004 to 0.027 mm (0.000157 to 0.00106 in.)
Maximum 0.10 mm (0.00394 in.)
Piston pin hole inside diameter Mark A 22.001 to 22.004 mm (0.86618 to 0.86630 in.)
Mark B 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
Mark C 22.008 to 22.010 mm (0.86645 to 0.86653 in.)
Standard ring groove clearance No. 1 compression ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 compression ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
Oil ring 0.060 to 0.120 mm (0.00236 to 0.00472 in.)
Piston ring Standard end gap No. 1 compression ring 0.22 to 0.27 mm (0.00866 to 0.0106 in.)
No. 2 compression ring 0.50 to 0.55 mm (0.0197 to 0.0217 in.)
Oil ring (Side rail) 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum end gap No. 1 compression ring 0.87 mm (0.0342 in.)
No. 2 compression ring 1.15 mm (0.0453 in.)
Oil ring (Side rail) 0.95 mm (0.0374 in.)
Piston pin Standard diameter Mark A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
Mark B 22.001 to 22.003 mm (0.86617 to 0.86626 in.)
Mark C 22.004 to 22.006 mm (0.86630 to 0.86638 in.)
Oil clearance (Piston side) Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum 0.013 mm (0.000512 in.)
Oil clearance (Connecting rod side) Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.017 mm (0.000669 in.)
Crankshaft bearing cap set bolt Standard diameter 9.77 to 9.96 mm (0.385 to 0.392 in.)
Minimum diameter 9.1 mm (0.358 in.)
Connecting rod bolt Standard diameter 8.5 to 8.6 mm (0.335 to 0.339 in.)
Minimum diameter 8.3 mm (0.327 in.)
Ring pin Standard Protrusion Height A 5.0 to 7.0 mm (0.197 to 0.276 in.)
B 4.0 to 7.0 mm (0.157 to 0.276 in.)
Straight pins Standard Protrusion Height A 11.0 to 13.0 mm (0.433 to 0.512 in.)
B 5.0 to 7.0 mm (0.197 to 0.276 in.)