2GR-FE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminals 13 (TC) and 4 (CG) of the DLC3 connected 8 to 12 degrees BTDC at idle (Transaxle should be in neutral or park)
Terminals 13 (TC) and 4 (CG) of the DLC3 disconnected 7 to 24 degrees 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

1300 kPa (13.3 kgf/cm2, 189 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
ENGINE UNIT
Camshaft Runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Intake Standard 44.316 to 44.416 mm (1.7448 to 1.7486 in.)
Minimum 44.166 mm (1.7388 in.)
Exhaust Standard 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Minimum 44.112 mm (1.7366 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 (1.0221 to 1.0226 in.)
for Bank 1: Oil clearance No. 1 journal Standard 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
Maximum 0.10 mm (0.00394 in.)
Other journals Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.09 mm (0.00354 in.)
for Bank 2: Oil clearance No. 1 journal Standard 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
Maximum 0.10 mm (0.00394 in.)
Other journals Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.09 mm (0.00354 in.)
for Bank 1: Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
for Bank 2: Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
Cylinder head set bolt Diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4330 in.)
Minimum 10.70 mm (0.4212 in.)
Chain sub-assembly Elongation Maximum 136.9 mm (5.389 in.)
No. 2 chain sub-assembly Elongation Maximum 137.6 mm (5.417 in.)
Crankshaft timing sprocket Diameter (with Chain sub-assembly) Minimum 61.4 mm (2.418 in.)
Idle sprocket assembly Diameter (with Chain sub-assembly) Minimum 61.4 mm (2.418 in.)
Idle gear shaft No. 1 idle gear shaft diameter Standard 22.987 to 23.000 mm (0.9050 to 0.9055 in.)
Idle sprocket assembly inside diameter Standard 23.020 to 23.030 mm (0.9063 to 0.9067 in.)
Oil clearance Standard 0.020 to 0.043 mm (0.000787 to 0.00169 in.)
Maximum 0.093 mm (0.00366 in.)
No. 2 chain tensioner assembly Wear depth Maximum 0.9 mm (0.0354 in.)
No. 3 chain tensioner assembly Wear depth Maximum 0.9 mm (0.0354 in.)
Chain tensioner slipper Wear depth Maximum 1.0 mm (0.0394 in.)
No. 1 chain vibration damper Wear depth Maximum 1.0 mm (0.0394 in.)
No. 2 chain vibration damper Wear depth Maximum 1.0 mm (0.0394 in.)
Exhaust manifold sub-assembly Warpage Maximum 0.7 mm (0.0276 in.)
Intake manifold Warpage Maximum 0.1 mm (0.00394 in.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Standard Bottom Side 0.05 mm (0.00197 in.)
Standard Intake Manifold Side 0.08 mm (0.00315 in.)
Standard Exhaust Manifold Side 0.08 mm (0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Intake valve Valve stem diameter Standard 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.5 mm (0.0197 in.)
Overall length Standard 105.85 mm (4.1673 in.)
Minimum 105.35 mm (4.1476 in.)
Exhaust valve Valve stem diameter Standard 5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.5 mm (0.0197 in.)
Overall length Standard 110.40 mm (4.3464 in.)
Minimum 109.90 mm (4.3268 in.)
Inner compression spring Free length Standard 50.55 mm (1.9902 in.)
Deviation Maximum 1.4 mm (0.0551 in.)
Angle (Reference) Maximum 2°
Intake valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.08 mm (0.00315 in.)
Bush bore diameter Use STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
Use O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Protrusion height Standard 9.30 to 9.70 mm (0.3661 to 0.3819 in.)
Exhaust valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.10 mm (0.00394 in.)
Bush bore diameter Use STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
Use O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Protrusion height Standard 9.30 to 9.70 mm (0.3661 to 0.3819 in.)
Ring pin for cylinder head sub-assembly Protrusion height Standard 2.5 to 3.5 mm (0.0984 to 0.138 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 0.0157 in.)
Maximum 0.50 mm (0.0197 in.)
Connecting rod oil clearance Standard 0.045 to 0.067 mm (0.00177 to 0.00264 in.)
Maximum 0.070 mm (0.00276 in.)
Connecting rod diameter Mark 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
Mark 2 56.007 to 56.012 mm (2.20500 to 2.20519 in.)
Mark 3 56.013 to 56.018 mm (2.20523 to 2.20543 in.)
Mark 4 56.019 to 56.024 mm (2.20547 to 2.20566 in.)
Connecting rod bearing center wall thickness (13281-31070, 13281-31110) 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.)
Connecting rod bearing center wall thickness (13281-31100) Mark 1 1.482 to 1.485 mm (0.05835 to 0.05846 in.)
Mark 2 1.485 to 1.488 mm (0.05846 to 0.05858 in.)
Mark 3 1.488 to 1.491 mm (0.05858 to 0.05870 in.)
Mark 4 1.491 to 1.494 mm (0.05870 to 0.05882 in.)
Crankshaft pin diameter Standard 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Cylinder block warpage Maximum 0.07 mm (0.00276 in.)
Cylinder bore diameter Reference diameter (New parts) 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum 94.13 mm (3.7059 in.)
Piston diameter Reference diameter (New parts) 93.960 to 93.980 mm (3.6992 to 3.7000 in.)
Minimum 93.830 mm (3.6941 in.)
Piston oil clearance Reference oil clearance (New parts) 0.020 to 0.052 mm (0.000787 to 0.00205 in.)
Maximum 0.060 mm (0.00236 in.)
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 0.070 to 0.150 mm (0.00276 to 0.00591 in.)
Piston pin hole inside diameter Mark A 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
Mark B 22.004 to 22.007 mm (0.8663 to 0.8664 in.)
Mark C 22.007 to 22.010 mm (0.8664 to 0.8665 in.)
Piston pin diameter Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 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.)
Piston pin oil clearance Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum 0.015 mm (0.000591 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 (0.000197 to 0.000433 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 compression ring Standard 0.22 to 0.32 mm (0.00866 to 0.0126 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 compression ring Standard 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Maximum 0.85 mm (0.0335 in.)
Oil ring Standard 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
Maximum 0.60 mm (0.0236 in.)
Connecting rod sub-assembly misalignment Maximum 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
Connecting rod sub-assembly 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 runout Maximum 0.06 mm (0.00236 in.)
Crankshaft 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 (0.000787 in.)
Crank pin Crank pin diameter Standard 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crankshaft oil clearance Standard 0.026 to 0.047 mm (0.00102 to 0.00185 in.)
Maximum 0.050 mm (0.00197 in.)
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 crankshaft bearing center wall thickness (No. 1 and No. 4 journal) except Part No. 11701-31100 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.)
Part No. 11701-31100 Mark 1 2.497 to 2.500 mm (0.09831 to 0.09843 in.)
Mark 2 2.501 to 2.503 mm (0.09846 to 0.09854 in.)
Mark 3 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
Mark 4 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
Mark 5 2.510 to 2.512 mm (0.09882 to 0.09890 in.)
Standard lower crankshaft bearing center wall thickness (No. 1 and No. 4 journal) except Part No. 11701-31100 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.)
Part No. 11701-31100 Mark 1 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 2 2.482 to 2.484 mm (0.09772 to 0.09780 in.)
Mark 3 2.485 to 2.487 mm (0.09783 to 0.09791 in.)
Mark 4 2.488 to 2.490 mm (0.09795 to 0.09803 in.)
Mark 5 2.491 to 2.493 mm (0.09807 to 0.09815 in.)
Standard upper crankshaft bearing center wall thickness (No. 2 and No. 3 journal) except Part No. 11071-31060 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.)
Part No. 11071-31060 Mark 1 2.476 to 2.479 mm (0.09748 to 0.09760 in.)
Mark 2 2.480 to 2.482 mm (0.09764 to 0.09772 in.)
Mark 3 2.483 to 2.485 mm (0.09776 to 0.09783 in.)
Mark 4 2.486 to 2.488 mm (0.09787 to 0.09795 in.)
Mark 5 2.489 to 2.491 mm (0.09799 to 0.09807 in.)
Standard lower crankshaft bearing center wall thickness (No. 2 and No. 3 journal) except Part No. 11071-31060 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.)
Part No. 11071-31060 Mark 1 2.493 to 2.496 mm (0.09815 to 0.09827 in.)
Mark 2 2.497 to 2.499 mm (0.09831 to 0.09839 in.)
Mark 3 2.500 to 2.502 mm (0.09843 to 0.09850 in.)
Mark 4 2.503 to 2.505 mm (0.09854 to 0.09862 in.)
Mark 5 2.506 to 2.508 mm (0.09866 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.)
Straight pin for cylinder block sub-assembly Protrusion height Pin (A) 23 mm (0.906 in.)
Pin (B) 6 mm (0.236 in.)
Pin (C) 11 mm (0.433 in.)
Pin (D) 9 mm (0.354 in.)
Connecting rod small end bush oil clearance Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)