4GR-FSE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Connect terminals 13 (TC) and 4 (CG) of the DLC3 Standard 8 to 12 degrees BTDC at idle
Disconnect terminals 13 (TC) and 4 (CG) of the DLC3 Standard 7 to 17 degrees BTDC at idle
Idle speed Standard 600 to 700 rpm
Compression pressure Standard pressure

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

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

100 kPa (1.0 kgf/cm2, 15 psi)
ENGINE ASSEMBLY
Exhaust manifold sub-assembly Maximum warpage 0.70 mm (0.02756 in.)
ENGINE UNIT
Camshaft Circuit runout Maximum 0.08 mm (0.00315 in.)
Cam lobe height Intake Standard 43.940 to 44.040 mm (1.7299 to 1.7339 in.)
Maximum 43.790 mm (1.7240 in.)
Exhaust Standard 44.090 to 44.190 mm (1.7358 to 1.7398 in.)
Maximum 43.940 mm (1.7299 in.)
Exhaust (for fuel pump) Standard 56.450 to 56.550 mm (2.2224 to 2.2264 in.)
Maximum 56.300 mm (2.2165 in.)
Journal diameter 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.)
for Bank 1: Oil clearance Exhaust side No. 1 journal Standard 0.031 to 0.078 mm (0.00122 to 0.00307 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.)
for Bank 2: Oil clearance Exhaust side No. 1 journal Standard 0.031 to 0.078 mm (0.00122 to 0.00307 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 assembly 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 0.70 mm (0.0276 in.)
Intake Manifold Warpage Maximum 0.10 mm (0.00394 in.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Standard Cylinder Block Sub-assembly Side 0 to 0.05 mm (0 to 0.00197 in.)
Standard Intake Side 0 to 0.08 mm (0 to 0.00315 in.)
Standard Exhaust Side 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 106.15 mm (4.18 in.)
Minimum 105.65 mm (4.16 in.)
Exhaust valve Valve stem diameter Standard 5.465 to 5.480 mm (0.215 to 0.216 in.)
Margin thickness Standard 0.81 mm (0.0319 in.)
Minimum 0.31 mm (0.0122 in.)
Overall length Standard 111.70 mm (4.40 in.)
Minimum 111.20 mm (4.38 in.)
Inner compression spring Free length Standard 57.46 mm (2.26 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 0.030 to 0.060 mm (0.00118 to 0.00236 in.)
Maximum 0.08 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 10.2 to 10.6 mm (0.402 to 0.417 in.)
Exhaust valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Standard 0.025 to 0.065 mm (0.00098 to 0.00256 in.)
Maximum 0.01 mm (0.00039 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 9.30 to 9.70 mm (0.366 to 0.382 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 3.8 mm (0.0984 to 0.150 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 0.25 to 0.40 mm (0.00984 to 0.0158 in.)
Maximum 0.50 mm (0.0197 in.)
Connecting rod oil clearance Standard 0.026 to 0.046 mm (0.00102 to 0.00181 in.)
Maximum 0.070 mm (0.00276 in.)
Connecting rod diameter Mark 1 51.000 to 51.006 mm (2.00787 to 2.00811 in.)
Mark 2 51.007 to 51.012 mm (2.00815 to 2.00834 in.)
Mark 3 51.013 to 51.018 mm (2.00838 to 2.00858 in.)
Mark 4 51.019 to 51.024 mm (2.00862 to 2.00881 in.)
Connecting rod beating center wall thickness Mark 1 1.484 to 1.487 mm (0.05843 to 0.05854 in.)
Mark 2 1.487 to 1.490 mm (0.05854 to 0.05866 in.)
Mark 3 1.490 to 1.493 mm (0.05866 to 0.05878 in.)
Mark 4 1.493 to 1.496 mm (0.05878 to 0.05890 in.)
Crankshaft pin diameter Standard 47.992 to 48.000 mm (1.8894 to 1.8898 in.)
Cylinder block warpage Standard 0 to 0.05 mm (0 to 0.00197 in.)
Maximum 0.07 mm (0.00276 in.)
Cylinder bore diameter Reference value (New parts) 83.000 to 83.012 mm (3.2677 to 3.2682 in.)
Maximum 83.13 mm (3.27 in.)
Piston diameter Distance 14.3 mm (0.563 in.)
Reference value (New parts) 82.960 to 82.970 mm (3.2661 to 3.2665 in.)
Minimum 82.846 mm (3.2616 in.)
Piston oil clearance Reference value (New parts) 0.030 to 0.052 mm (0.00118 to 0.00205 in.)
Maximum 0.072 mm (0.00284 in.)
Piston ring groove clearance No. 1 0.020 to 0.070 mm (0.00079 to 0.00276 in.)
No. 2 0.030 to 0.070 mm (0.00118 to 0.00276 in.)
Oil 0.020 to 0.070 mm (0.00079 to 0.00276 in.)
Piston pin hole inside diameter Mark A 21.998 to 22.001 mm (0.86606 to 0.86618 in.)
Mark B 22.002 to 22.004 mm (0.86622 to 0.86630 in.)
Mark C 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
Piston pin diameter Mark A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
Mark B 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
Mark C 22.004 to 22.006 mm (0.86630 to 0.86638 in.)
Piston pin oil clearance Standard -0.002 to 0.004 mm (-0.00008 to 0.00016 in.)
Maximum 0.015 mm (0.00059 in.)
Connecting rod bushing 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.)
Connecting rod bushing oil clearance Standard 0.005 to 0.011 mm (0.00020 to 0.00043 in.)
Maximum 0.030 mm (0.00118 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 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Piston ring end gap No. 1 Standard 0.20 to 0.25 mm (0.00787 to 0.00984 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 Standard 0.35 to 0.40 mm (0.01378 to 0.01575 in.)
Maximum 0.80 mm (0.0315 in.)
Oil Standard 0.10 to 0.20 mm (0.00394 to 0.0787 in.)
Maximum 0.65 mm (0.0256 in.)
Connecting rod out-of alignment 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.)
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 circle runout Maximum 0.06 mm (0.00236 in.)
Crank main journal Journal diameter Standard 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
Taper and out-of-round Maximum 0.02 mm (0.00079 in.)
Crank pin Crank pin diameter Standard 47.992 to 48.000 mm (1.889 to 1.890 in.)
Taper and out-of-round Maximum 0.02 mm (0.00079 in.)
Crankshaft oil clearance Standard 0.026 to 0.047 mm (0.00102 to 0.00185 in.)
Maximum 0.050 mm (0.00197 in.)
Standard Cylinder Block 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 (2.59874 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.)
Standard Crankshaft 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.)
Standard upper bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
Mark 2 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
Mark 3 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
Mark 4 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
Mark 5 2.512 to 2.515 mm (0.09890 to 0.09902 in.)
Standard lower bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 2 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
Mark 3 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
Mark 4 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
Mark 5 2.490 to 2.493 mm (0.09803 to 0.09815 in.)
Standard upper bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 2 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
Mark 3 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
Mark 4 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
Mark 5 2.490 to 2.493 mm (0.09803 to 0.09815 in.)
Standard lower bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
Mark 2 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
Mark 3 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
Mark 4 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
Mark 5 2.512 to 2.515 mm (0.09890 to 0.09902 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 for cylinder block sub-assembly Protrusion height Pin A 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B 5.5 to 6.5 mm (0.217 to 0.256 in.)
Pin C 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin D 8.5 to 9.5 mm (0.335 to 0.374 in.)