2ZR-FXE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition Timing Terminals 13 (TC) and 4 (CG) of DLC3 connected 8 to 12°BTDC at idle
Terminals 13 (TC) and 4 (CG) of DLC3 disconnected 8 to 24°BTDC at idle
Idle Speed 950 to 1050 rpm
Compression Standard pressure

813 kPa (8.3 kgf/cm2, 118 psi)
Minimum pressure

617 kPa (6.3 kgf/cm2, 89.5 psi)
Difference between each cylinder

100 kPa (1.0 kgf/cm2, 15 psi) or less
FRONT CRANKSHAFT OIL SEAL
Timing chain cover oil seal Tap in depth -1.0 to 1.0 mm (-0.0394 to 0.0394 in.)
REAR CRANKSHAFT OIL SEAL
Rear engine oil seal Tap in depth -1.0 to 1.0 mm (-0.0394 to 0.0394 in.)
ENGINE UNIT
Chain sub-assembly Elongation Maximum 115.2 mm (4.54 in.)
No. 2 chain sub-assembly Elongation Maximum 102.1 mm (4.02 in.)
Oil pump drive gear Diameter (with Chain) Minimum 48.2 mm (1.90 in.)
Oil pump drive shaft gear Diameter (with Chain) Minimum 48.2 mm (1.90 in.)
Camshaft timing gear assembly Diameter (with Chain) Minimum 96.8 mm (3.81 in.)
Camshaft timing exhaust gear assembly Diameter (with Chain) Minimum 96.8 mm (3.81 in.)
Crankshaft timing sprocket 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.)
Cylinder head set 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.)
Camshaft Runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height Standard 42.816 to 42.916 mm (1.6857 to 1.6896 in.)
Minimum 42.766 mm (1.6837 in.)
Journal diameter No. 1 journal Standard 34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other journals Standard 22.949 to 22.965 mm (0.90350 to 0.90413 in.)
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 journals Standard 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum 0.09 mm (0.00354 in.)
No. 2 camshaft Runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height Standard 43.344 to 43.444 mm (1.7065 to 1.7104 in.)
Minimum 43.294 mm (1.7045 in.)
Journal diameter No. 1 journal Standard 34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other journals Standard 22.949 to 22.965 mm (0.90350 to 0.90413 in.)
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 journals Maximum 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 (0.0276 in.)
Ring pin for stiffening crankcase assembly Protrusion height Standard 3.0 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.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Bottom 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.)
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 Standard 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.)
Inner compression spring Free length Standard 58.52 mm (2.30 in.) or 58.90 mm (2.32 in.)
Angle (Reference) Maximum 2°
Valve guide bush Bush 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.)
Bush Bore diameter for cylinder head sub-assembly Intake Standard 10.285 to 10.306 mm (0.40492 to 0.40575 in.)
Use STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
Use O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)
Exhaust Standard 10.285 to 10.306 mm (0.40492 to 0.40575 in.)
Use STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
Use O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)
Protrusion height Intake Standard 9.9 to 10.3 mm (0.390 to 0.406 in.)
Exhaust Standard 11.15 to 11.55 mm (0.439 to 0.455 in.)
Intake valve seat Width Standard 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust valve seat Width Standard 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Ring pin for cylinder head cover sub-assembly Protrusion Height Standard 11.7 to 12.3 mm (0.461 to 0.484 in.)
Spark Plug Tube Protrusion Height Standard 122 mm (4.80 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.)
Connecting rod oil clearance Standard 0.014 to 0.038 mm (0.000551 to 0.00150 in.)
Maximum 0.070 mm (0.00276 in.)
Standard connecting rod large end bore diameter Mark 1 47.000 to 47.008 mm (1.85039 to1.85070 in.)
Mark 2 47.009 to 47.016 mm (1.85074 to1.85102 in.)
Mark 3 47.017 to 47.024 mm (1.85106 to1.85133 in.)
Standard connecting rod bearing thickness Mark 1 1.489 to 1.493 mm (0.05862 to 0.05878 in.)
Mark 2 1.494 to 1.497 mm (0.05882 to 0.05894 in.)
Mark 3 1.498 to 1.501 mm (0.05898 to 0.05909 in.)
Crank pin diameter Standard 43.992 to 44.000 mm (1.73197 to 1.73228 in.)
Crankshaft thrust clearance Standard 0.04 to 0.14 mm (0.00157 to 0.00551 in.)
Maximum 0.18 mm (0.00709 in.)
Crankshaft thrust washer thickness Standard 2.43 to 2.48 mm (0.0957 to 0.976 in.)
Crankshaft oil clearance Standard 0.014 to 0.038 mm (0.000551 to 0.0015 in.)
Standard cylinder block journal bore diameter Mark 0 52.000 to 52.002 mm (2.04724 to 2.04732 in.)
Mark 1 52.003 to 52.004 mm (2.04736 to 2.04740 in.)
Mark 2 52.005 to 52.006 mm (2.04744 to 2.04748 in.)
Mark 3 52.007 to 52.009 mm (2.04752 to 2.04759 in.)
Mark 4 52.010 to 52.011 mm (2.04763 to 2.04767 in.)
Mark 5 52.012 to 52.013 mm (2.04771 to 2.04775 in.)
Mark 6 52.014 to 52.016 mm (2.04779 to 2.04787 in.)
Standard crankshaft journal diameter Mark 0 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
Mark 1 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
Mark 2 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
Mark 3 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
Mark 4 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
Mark 5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Standard crankshaft bearing center wall thickness Mark 1 1.991 to 1.994 mm (0.07839 to 0.07850 in.)
Mark 2 1.995 to 1.997 mm (0.07854 to 0.07862 in.)
Mark 3 1.998 to 2.000 mm (0.07866 to 0.07874 in.)
Mark 4 2.001 to 2.003 mm (0.07878 to 0.07886 in.)
Cylinder block sub-assembly warpage Maximum 0.05 mm (0.00197 in.)
Cylinder bore diameter (New Parts) Reference 80.500 to 80.513 mm (3.16929 to 3.16980 in.)
Maximum 80.63 mm (3.17 in.)
Piston diameter (New Parts) Reference 80.473 to 80.503 mm (3.16822 to 3.16940 in.)
Piston oil clearance (New Parts) Reference -0.003 to 0.040 mm (-0.000118 to 0.00157 in.)
Maximum 0.08 mm (0.00315 in.)
Piston ring groove clearance No. 1 compression ring Standard 0.02 to 0.07 mm (0.000787 to 0.00276 in.)
No. 2 compression ring (Mark 2R) Standard 0.02 to 0.055 mm (0.000787 to 0.00217 in.)
No. 2 compression ring (Mark 2T) 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 compression ring (Mark 1R) Standard 0.24 to 0.28 mm (0.00945 to 0.0110 in.)
Maximum 0.5 mm (0.0197 in.)
No. 1 compression ring (Mark -) Standard 0.20 to 0.25 mm (0.00787 to 0.00984 in.)
Maximum 0.5 mm (0.0197 in.)
No. 2 compression ring (Mark 2R) Standard 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
Maximum 0.7 mm (0.0276 in.)
No. 2 compression ring (Mark 2T) Standard 0.30 to 0.50 mm (0.0118 to 0.0197 in.)
Maximum 0.7 mm (0.276 in.)
Oil ring Standard 0.10 to 0.35 mm (0.00394 to 0.01378 in.)
Maximum 0.7 mm (0.276 in.)
Standard piston pin bore diameter Mark A 20.006 to 20.009 mm (0.78764 to 0.78775 in.)
Mark B 20.010 to 20.012 mm (0.78779 to 0.78787 in.)
Mark C 20.013 to 20.015 mm (0.78791 to 0.78799 in.)
Standard piston pin diameter Mark A 20.004 to 20.007 mm (0.78756 to 0.78768 in.)
Mark B 20.008 to 20.010 mm (0.78772 to 0.78779 in.)
Mark C 20.011 to 20.013 mm (0.78783 to 0.7879 1in.)
Standard connecting rod small end bore diameter Mark A 20.012 to 20.015 mm (0.78787 to 0.78799 in.)
Mark B 20.016 to 20.018 mm (0.78803 to 0.78811 in.)
Mark C 20.019 to 20.021 mm (0.78815 to 0.78823 in.)
Piston pin oil clearance Piston side Standard -0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)
Maximum 0.010 mm (0.000394 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 bolt diameter Standard 6.6 to 6.7 mm (0.260 to 0.264 in.)
Maximum 6.4 mm (0.252 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.)
Crankshaft runout Maximum 0.03 mm (0.00118 in.)
Cramkshaft diameter Standard 47.988 to 48.000 mm (1.88929 to 1.88976 in.)
Crankshaft journal Taper and out-of-round Maximum 0.004 mm (0.000157 in.)
Standard crankshaft journal diameter Mark 0 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
Mark 1 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
Mark 2 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
Mark 3 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
Mark 4 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
Mark 5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Crank pin Taper and out-of-round Maximum 0.004 mm (0.000157 in.)
Crankshaft bearing cap set 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.)
Ring pin for cylinder block sub-assembly Protrusion Height Standard 14.3 to 14.7mm (0.563 to 0.579 in.)
Straight pin for cylinder block sub-assembly Protrusion Height Pin (A) 18.5 to 19.5 mm (0.728 to 0.768 in.)
Pin (B) 5.0 to 7.0 mm (0.197 to 0.276 in.)
Pin (C) 11 to 13 mm (0.433 to 0.512 in.)
Pin (D) 8.0 to 10.0 mm (0.315 to 0.394 in.)
Connecting rod small end bush oil clearance Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Crankshaft bearing Difference between (A) and (B) 0.5 to 1.0 mm (0.0197 to 0.0394 in.)
Dimension (A) 0.7 mm (0.0276 in.) or less
Difference between (A) and (B) 0.7 mm (0.0276 in.) or less
Connecting rod bearing Difference between (A) and (B) 0 to 0.7 mm (0 to 0.0276 in.)