3ZR-FE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminal TC and CG of DLC3 connected 8 to 12° BTDC @ idle
Idle speed Standard idle speed 600 to 700 rpm
Compression Standard compression pressure

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

1079 kPa (11.0 kgf/cm2, 156 psi)
Difference between each cylinder

98 kPa (1.0 kgf/cm2, 14.2 psi) or less
DRIVE BELT

Deflection

Pressing force: 98 N (10 kgf, 22 lbf)

 New belt 7.0 to 8.2 mm (0.276 to 0.323 in.)
Used belt 7.6 to 10 mm (0.299 to 0.394 in.)

Tension

Pressing force: 98 N (10 kgf, 22 lbf)

 New belt 700 to 800 N (70 to 80 kgf, 157.4 to 179.8 lbf)
Used belt 550 to 750 N (55 to 75 kgf, 123.6 to 168.6 lbf)
CAMSHAFT
No. 1 camshaft bearing Dimension (A - B) or (B - A) 0 to 0.7 mm (0 to 0.0276 in.)
No. 2 camshaft bearing Dimension (A) 1.05 to 1.75 mm (0.0413 to 0.0689 in.)
ENGINE UNIT
Chain sub-assembly Chain elongation Maximum 115.2 mm (4.54 in.)
No. 2 chain sub-assembly Chain elongation Maximum 102.1 mm (4.02 in.)
Oil pump drive gear Gear diameter (with chain) Minimum 48.2 mm (1.90 in.)
Oil pump drive shaft gear Gear diameter (with chain) Minimum 48.2 mm (1.90 in.)
Camshaft timing gear assembly Gear diameter (with chain) Minimum 96.8 mm (3.81 in.)
Camshaft timing exhaust gear assembly Gear diameter (with chain) Minimum 96.8 mm (3.81 in.)
Crankshaft timing gear Gear diameter (with chain) Minimum 51.1 mm (2.01 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.)
Camshaft Circle runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Standard 42.816 to 42.916 mm (1.686 to 1.690 in.)
Minimum 42.666 mm (1.680 in.)
Journal diameter No. 1 Standard 34.449 to 34.465 mm (1.356 to 1.357 in.)
Other Standard 22.949 to 22.965 mm (0.9035 to 0.9041 in.)
No. 2 camshaft Circle runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Standard 44.336 to 44.436 mm (1.746 to 1.750 in.)
Minimum 44.186 mm (1.740 in.)
Journal diameter No. 1 Standard 34.449 to 34.465 mm (1.356 to 1.357 in.)
Other Standard 22.949 to 22.965 mm (0.9035 to 0.9041 in.)
Cylinder head bolt Length Standard 146.8 to 148.2 mm (5.78 to 5.83 in.)
Maximum 149.2 mm (5.87 in.)
Diameter Standard 9.77 to 9.96 mm (0.385 to 0.392 in.)
Minimum 9.4 mm (0.370 in.)
Exhaust manifold Warpage Maximum 0.7 mm (0.0276 in.)
CYLINDER HEAD
Cylinder head Warpage Cylinder head lower 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.)
Camshaft Thrust clearance Standard 0.06 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum 0.17 mm (0.00669 in.)
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 journal Standard 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum 0.09 mm (0.00354 in.)
Compression spring Free length Standard 51.9 mm (2.04 in.)
Deviation Maximum 1.3 mm (0.0512 in.)
Intake valve Overall length Standard 109.34 mm (4.30 in.)
Minimum 108.84 mm (4.29 in.)
Valve stem diameter Standard 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.)
Exhaust valve Overall length Maximum 108.25 mm (4.26 in.)
Minimum 107.75 mm (4.24 in.)
Valve stem diameter Standard 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.)
Valve guide bush Bushing inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Intake Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.080 mm (0.00315 in.)
Exhaust Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.085 mm (0.00335 in.)
Spark plug tube Protrusion height Standard 122 mm (4.80 in.)
Valve seat Width 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
CYLINDER BLOCK
Connecting rod Thrust clearance Standard 0.160 to 0.342 mm (0.00630 to 0.0135 in.)
Maximum 0.342 mm (0.0135 in.)
Oil clearance Standard 0.030 to 0.062 mm (0.00118 to 0.00244 in.)
Maximum 0.070 mm (0.00276 in.)
Connecting rod large end bore Diameter Mark 1 Standard 50.000 to 50.008 mm (1.9685 to 1.9688 in.)
Mark 2 Standard 50.008 to 50.016 mm (1.9688 to 1.9691 in.)
Mark 3 Standard 50.016 to 50.024 mm (1.9691 to 1.9694 in.)
Connecting rod bearing Thickness Mark 1 Standard 1.489 to 1.493 mm (0.0586 to 0.0588 in.)
Mark 2 Standard 1.493 to 1.497 mm (0.0588 to 0.0589 in.)
Mark 3 Standard 1.497 to 1.501 mm (0.0589 to 0.0591 in.)
Crankshaft pin Diameter Standard 46.992 to 47.000 mm (1.8501 to 1.8504 in.)
Crankshaft Thrust clearance Standard 0.04 to 0.14 mm (0.00157 to 0.00551 in.)
Maximum 0.18 mm (0.00709 in.)
Cylinder block Warpage Maximum 0.05 mm (0.00197 in.)
Cylinder bore Diameter Standard 80.500 to 80.513 mm (3.169 to 3.170 in.)
Maximum 80.633 mm (3.1745 in.)
Piston Diameter Standard 80.471 to 80.491 mm (3.168 to 3.169 in.)
Oil clearance Standard 0.009 to 0.042 mm (0.000354 to 0.00165 in.)
Maximum 0.08 mm (0.00315 in.)
Piston ring Ring groove clearance No. 1 compression ring Standard 0.02 to 0.07 mm (0.000787 to 0.00276 in.)
No. 2 compression ring Standard 0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Oil ring Standard 0.07 to 0.12 mm (0.00276 to 0.00472 in.)
End gap Type Y No. 1 compression ring Standard 0.20 to 0.30 mm (0.00787 to 0.0118 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 compression 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.)
Type Z No. 1 compression ring Standard 0.20 to 0.25 mm (0.00787 to 0.00984 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 compression 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 bore Diameter 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 pin Diameter 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.)
Connecting rod small end bore Diameter 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.)
Piston pi oil clearance Piston side Standard -0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)
Maximum 0.008 mm (0.000315 in.)
Connecting rod side Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.014 mm (0.000551 in.)
Connecting rod alighment Misalignment Maximum 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
Twist Maximum 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Crankshaft Circle runout Maximum 0.03 mm (0.00118 in.)

Taper and distortion

(Main journal side)

 Maximum 0.004 mm (0.000157 in.)
Main journal diameter 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.)

Taper and distortion

(Crank pin side)

 Maximum 0.004 mm (0.000157 in.)
Oil clearance Standard 0.016 to 0.039 mm (0.000630 to 0.00154 in.)
Maximum 0.050 mm (0.00197 in.)
Cylinder block journal bore Diameter 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.)
Crankshaft journal Diameter 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.)
Bearing center wall Thickness 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.)
Crankshaft bearing cap bolt Length Standard 84.3 to 85.7 mm (3.32 to 3.37 in.)
Maximum 86.7 mm (3.41 in.)
Diameter Standard 9.77 to 9.96 mm (0.385 to 0.392 in.)
Maximum 9.1 mm (0.358 in.)
Connecting rod bolt Diameter Standard 6.6 to 6.7 mm (0.260 to 0.264 in.)
Minimum 6.4 mm (0.252 in.)
Crankshaft bearing Upper bearing

Dimension (A)

(except No. 3 journal)

 0.5 to 1.0 mm (0.0197 to 0.0394 in.)

Dimension (A - B) or (B - A)

(for No. 3 journal)

 0 to 0.5 mm (0 to 0.0197 in.)
Lower bearing Dimension (A - B) or (B - A) 0 to 0.5 mm (0 to 0.0197 in.)
Connecting rod bearing Dimension (A - B) or (B - A) 0 to 0.7 mm (0 to 0.0276 in.)