2GR-FKS ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminals 13 (TC) and 4 (CG) of the DLC3 connected 8 to 12° BTDC at idle (Transaxle should be in neutral or park)
Terminals 13 (TC) and 4 (CG) of the DLC3 disconnected 15 to 25° BTDC at idle (Transaxle should be in neutral or park)
Engine idle speed 600 to 700 rpm (Transaxle should be in neutral or park)
Compression Standard compression pressure

1400 kPa (14.3 kgf/cm2, 203 psi)
Minimum compression pressure

980 kPa (10.0 kgf/cm2, 142 psi)
Pressure difference between each cylinder

100 kPa (1.0 kgf/cm2, 15 psi) or less
FRONT CRANKSHAFT OIL SEAL
Timing chain case oil seal Protrusion height Standard 0 to 1.0 mm (0 to 0.0394 in.)
REAR CRANKSHAFT OIL SEAL
Rear engine oil seal Protrusion height Standard -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
ENGINE UNIT
Camshaft Circuit runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height(for Bank 1) Intake Standard 44.3229 to 44.4229 mm (1.744 to 1.748 in.)
Minimum 44.2229 mm (1.741 in.)
Exhaust Standard 44.4377 to 44.5377 mm (1.749 to 1.753 in.)
Minimum 44.3377 mm (1.746 in.)
Exhaust (for fuel pump) Standard 40.554 to 40.654 mm (1.597 to 1.601 in.)
Minimum 40.454 mm (1.593 in.)
Cam lobe height(for Bank 2) Intake Standard 44.3221 to 44.4221 mm (1.744 to 1.748 in.)
Minimum 44.2221 mm (1.741 in.)
Exhaust Standard 44.4356 to 44.5356 mm (1.749 to 1.753 in.)
Minimum 44.3356 mm (1.745 in.)
Journal diameter(for Exhaust Side of Bank 1) No. 1 journal Standard 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals Standard 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
Journal diameter(except Exhaust Side of Bank 1) No. 1 journal Standard 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
No. 2, 3, 4 Journals Standard 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
No. 5 journal Standard 25.969 to 25.985 mm (1.022 to 1.023 in.)
Oil clearance(for Bank 1) No. 1 journal Standard 0.040 to 0.063 mm (0.00157 to 0.00248 in.)
Maximum 0.10 mm (0.00394 in.)
No. 2, 3, 4 Journals Standard 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
Maximum 0.09 mm (0.00354 in.)
No. 5 journal Standard 0.015 to 0.052 mm (0.000591 to 0.00205 in.)
Maximum 0.09 mm (0.00354 in.)
Oil clearance(for Bank 2) No. 1 journal Standard 0.032 to 0.071 mm (0.00126 to 0.00280 in.)
Maximum 0.10 mm (0.00394 in.)
Other journals Standard 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
Maximum 0.09 mm (0.00354 in.)
Cylinder head set bolt Length Standard 141.3 to 142.7 mm (5.56 to 5.62 in.)
Maximum 143.7 mm (5.66 in.)
Diameter Standard 10.80 to 11.00 mm (0.425 to 0.433 in.)
Minimum 10.70 mm (0.421 in.)
Chain sub-assembly Elongation Maximum 136.9 mm (5.39 in.)
No. 2 chain sub-assembly Elongation Maximum 137.6 mm (5.42 in.)
Crankshaft timing gear or sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.42 in.)
Idle sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.42 in.)
Idle gear shaft No. 1 idle gear shaft diameter Standard 22.987 to 23.000 mm (0.905 to 0.906 in.)
Idle sprocket assembly inside diameter Standard 23.020 to 23.030 mm (0.906 to 0.907 in.)
Oil clearance Standard 0.020 to 0.043 mm (0.00079 to 0.00169 in.)
Maximum 0.093 mm (0.00366 in.)
No. 2 chain tensioner assembly Worn depth Maximum 0.9 mm (0.0354 in.)
No. 3 chain tensioner assembly Worn depth Maximum 0.9 mm (0.0354 in.)
Chain tensioner slipper Worn depth Maximum 1.0 mm (0.0394 in.)
No. 1 chain vibration damper Worn depth Maximum 1.0 mm (0.0394 in.)
No. 2 chain vibration damper Worn depth Maximum 1.0 mm (0.0394 in.)
Exhaust manifold sub-assembly Warpage Maximum 0.5 mm (0.0197 in.)
Intake Manifold Warpage Maximum 0.10 mm (0.00394 in.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Cylinder Block Side Standard 0 to 0.05 mm (0 to 0.00197 in.)
Intake Side Standard 0 to 0.08 mm (0 to 0.00315 in.)
Exhaust Side Standard 0 to 0.08 mm (0 to 0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Intake valve 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.)
Overall length Standard 105.85 mm (4.17 in.)
Minimum 105.35 mm (4.15 in.)
Exhaust valve 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.)
Overall length Standard 110.40 mm (4.35 in.)
Minimum 109.90 mm (4.33 in.)
Inner compression spring Free length Standard 52.63 to 56.43 mm (2.07 to 2.22 in.)
Deviation Maximum 1.0 mm (0.0394 in.)
Angle (reference) Maximum 2°
Intake valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Standard 0.025 to 0.060 mm(0.00098 to 0.00236 in.)
Maximum 0.080 mm (0.00315 in.)
Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height Standard 9.10 to 9.90 mm (0.358 to 0.390 in.)
Exhaust valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Standard 0.030 to 0.065 mm(0.00118 to 0.00256 in.)
Maximum 0.085 mm (0.00335 in.)
Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height Standard 9.10 to 9.90 mm (0.358 to 0.390 in.)
Camshaft Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
Ring pin for cylinder head sub-assembly Protrusion height Standard 2.5 to 3.5 mm (0.0984 to 0.1378 in.)
Straight pin for cylinder head sub-assembly Protrusion height Standard 17.5 to 19.5 mm (0.689 to 0.768 in.)
CYLINDER BLOCK
Connecting rod Thrust clearance Standard 0.15 to 0.40 mm (0.00591 to 0.0158 in.)
Maximum 0.50 mm (0.0197 in.)
Oil clearance Standard 0.032 to 0.052mm (0.00126 to 0.00205 in.)
Maximum 0.070 mm (0.00276 in.)
Diameter Mark 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
Mark 2 56.006 to 56.012 mm(2.2049 to 2.2051 in.)
Mark 3 56.012 to 56.018 mm(2.2051 to 2.2054 in.)
Mark 4 56.018 to 56.024 mm(2.2054 to 2.2056 in.)
Connecting rod beating Center wall thickness Mark 1 1.481 to 1.484 mm (0.05831 to 0.05843 in.)
Mark 2 1.484 to 1.487 mm (0.05843 to 0.05854 in.)
Mark 3 1.487 to 1.490 mm (0.05854 to 0.05866 in.)
Mark 4 1.490 to 1.493 mm (0.05866 to 0.05878 in.)
Crankshaft pin Diameter Standard 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Cylinder bore Diameter Reference value (New parts) 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum 94.200 mm (3.708 in.)
Piston Diameter Distance 9.2 mm (0.362 in.)
Reference value (New parts) 93.95 to 93.96 mm (3.698 to 3.699 in.)
Minimum 93.830 mm (3.6941 in.)
Oil clearance Reference value (New parts) 0.04 to 0.062 mm (0.00157 to 0.00244 in.)
Maximum 0.075 mm (0.00295 in.)
Piston ring Groove clearance No. 1 compression ring Standard 0.02 to 0.07 mm (0.00078 to 0.00276 in.)
No. 2 compression ring Standard 0.02 to 0.06 mm (0.00078 to 0.00236 in.)
Oil ring Standard 0.07 to 0.15 mm (0.00027 to 0.00591 in.)
End gap No. 1 compression ring Standard 0.22 to 0.27 mm (0.00866 to 0.01063 in.)
Maximum 0.5 mm (0.0197 in.)
No. 2 compression ring Standard 0.7 to 0.75 mm (0.0276 to 0.0295 in.)
Maximum 0.85 mm (0.0335 in.)
Oil ring Standard 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum 0.6 mm (0.0236 in.)
Piston pin Hole inside diameter Mark A 21.998 to 22.001 mm (0.86606 to 0.86618 in.)
Mark B 22.001 to 22.004 mm(0.8662 to 0.8663 in.)
Mark C 22.004 to 22.007 mm(0.8663 to 0.8664 in.)
Diameter Mark A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
Mark B 22.000 to 22.003 mm(0.8661 to 0.8663 in.)
Mark C 22.003 to 22.006 mm(0.8663 to 0.8664 in.)
Oil clearance Standard -0.002 to 0.004 mm (-0.00008 to 0.00016 in.)
Maximum 0.015 mm (0.00059 in.)
Connecting rod bush Inside diameter Mark A 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
Mark B 22.008 to 22.011 mm(0.8664 to 0.8665 in.)
Mark C 22.011 to 22.014 mm(0.8665 to 0.8666 in.)
Oil clearance Standard 0.005 to 0.011 mm (0.00020 to 0.00043 in.)
Maximum 0.030 mm (0.00118 in.)
Connecting rod Out-of alignment 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.)
Connecting rod bolt Diameter Standard 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum 7.0 mm (0.276 in.)
Crankshaft Thrust clearance Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness Standard 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Ccircle runout Maximum 0.06 mm (0.00236 in.)
Main journal diameter Mark 00 60.999 to 61.000 mm (2.40153 to 2.40157 in.)
Mark 01 60.998 to 60.999 mm (2.40149 to 2.40153 in.)
Mark 02 60.997 to 60.998 mm (2.40145 to 2.40149 in.)
Mark 03 60.996 to 60.997 mm (2.40141 to 2.40145 in.)
Mark 04 60.995 to 60.996 mm (2.40137 to 2.40141 in.)
Mark 05 60.994 to 60.995 mm (2.40133 to 2.40137 in.)
Mark 06 60.993 to 60.994 mm (2.40129 to 2.40133 in.)
Mark 07 60.992 to 60.993 mm (2.40126 to 2.40129 in.)
Mark 08 60.991 to 60.992 mm (2.40122 to 2.40126 in.)
Mark 09 60.990 to 60.991 mm (2.40118 to 2.40122 in.)
Mark 10 60.989 to 60.990 mm (2.40114 to 2.40118 in.)
Mark 11 60.988 to 60.989 mm (2.40110 to 2.40114 in.)
Main journal taper and out-of-round Maximum 0.02 mm (0.00079 in.)
Oil clearance No. 1, No. 4 Journal Standard 0.019 to 0.029 mm (0.00075 to 0.00114 in.)
Minimum 0.050 mm (0.00197 in.)
No. 2, No. 3 Journal Standard 0.025 to 0.035 mm(0.00098 to 0.00138 in.)
Minimum 0.060 mm (0.00236 in.)
Crank pin diameter Standard 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Crank pin taper and out-of-round Maximum 0.02 mm (0.00079 in.)
Cylinder block Warpage Standard 0 to 0.05 mm (0 to 0.00197 in.)
Maximum 0.07 mm (0.00276 in.)
Main journal bore diameter Mark 00 66.000 mm (2.59842 in.)
Mark 01 66.001 mm (2.59846 in.)
Mark 02 66.002 mm (2.59850 in.)
Mark 03 66.003 mm (2.59854 in.)
Mark 04 66.004 mm (2.59858 in.)
Mark 05 66.005 mm (2.59862 in.)
Mark 06 66.006 mm (2.59866 in.)
Mark 07 66.007 mm (2.59870 in.)
Mark 08 66.008 mm (2.59873 in.)
Mark 09 66.009 mm (2.59877 in.)
Mark 10 66.010 mm (2.59881 in.)
Mark 11 66.011 mm (2.59885 in.)
Mark 12 66.012 mm (2.59889 in.)
Mark 13 66.013 mm (2.59893 in.)
Mark 14 66.014 mm (2.59897 in.)
Mark 15 66.015 mm (2.59901 in.)
Mark 16 66.016 mm (2.59905 in.)
Crankshaft bearing Upper bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 Standard 2.497 to 2.500 mm (0.09831 to 0.09843 in.)
Mark 2 Standard 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
Mark 3 Standard 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
Mark 4 Standard 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
Mark 5 Standard 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
Lower bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 Standard 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 2 Standard 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
Mark 3 Standard 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
Mark 4 Standard 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
Mark 5 Standard 2.490 to 2.493 mm (0.09803 to 0.09815 in.)
Upper bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 Standard 2.476 to 2.479 mm (0.09748 to 0.09760 in.)
Mark 2 Standard 2.479 to 2.481 mm (0.09760 to 0.09768 in.)
Mark 3 Standard 2.481 to 2.485 mm (0.09768 to 0.09783 in.)
Mark 4 Standard 2.485 to 2.488 mm (0.09783 to 0.09795 in.)
Mark 5 Standard 2.488 to 2.491 mm (0.09795 to 0.09807 in.)
Lower bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 Standard 2.493 to 2.496 mm (0.09815 to 0.09827 in.)
Mark 2 Standard 2.496 to 2.499 mm (0.09827 to 0.09839 in.)
Mark 3 Standard 2.499 to 2.502 mm (0.09839 to 0.09850 in.)
Mark 4 Standard 2.502 to 2.505 mm (0.09850 to 0.09862 in.)
Mark 5 Standard 2.505 to 2.508 mm (0.09862 to 0.09874 in.)
Crankshaft bearing cap set bolt Diameter Standard 10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Minimum 10.7 mm (0.4213 in.)
Measuring point 47 mm (1.85 in.)
Straight pin Protrusion Pin A Standard 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B Standard 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C Standard 8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D Standard 5.5 to 6.5 mm (0.217 to 0.256 in.)