1GR-FE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminal TC and CG of DLC3 connected 8 to 12° BTDC @ idle
Terminals TC and CG of DLC3 disconnected 7 to 24° BTDC @ idle
Idle speed 650 to 750 rpm
Compression Standard

1300 kPa (13.3 kgf/cm2, 189 psi) or higher
Minimum

1000 kPa (10.2 kgf/cm2, 145 psi)
Difference

100 kPa (1.0 kgf/cm2, 15 psi) or less
VALVE CLEARANCE
Valve clearance Intake side Standard (cold) 0.15 to 0.25 mm (0.00591 to 0.00984 in.)
Exhaust side Standard (cold) 0.29 to 0.39 mm (0.0114 to 0.0154 in.)
ENGINE UNIT
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.)
Outside diameter Standard 10.85 to 11.0 mm (0.427 to 0.433 in.)
Minimum 10.7 mm (0.421 in.)
Camshaft Circle runout Maximum 0.06 mm (0.00236 in.)
Cam lobe height Intake Standard 44.168 to 44.268 mm (1.739 to 1.743 in.)
Minimum 44.018 mm (1.73 in.)
Exhaust Standard 44.580 to 44.680 mm (1.755 to 1.759 in.)
Minimum 44.430 mm (1.75 in.)
Journal diameter No. 1 journal Standard 35.971 to 35.985 mm (1.416 to 1.417 in.)
Other journal 22.959 to 22.975 mm (0.904 to 0.905 in.)
Timing chain No. 1 chain Chain elongation Maximum 146.8 mm (5.78 in.)
No. 2 chain 146.8 mm (5.78 in.)
Camshaft timing gear assembly Gear diameter (with chain) Minimum 115.5 mm (4.55 in.)
Gear diameter (with No. 2 chain) Minimum 73.1 mm (2.88 in.)
Camshaft timing sprocket Gear diameter (with No. 2 chain) Minimum 73.1 mm (2.88 in.)
Crankshaft timing sprocket Gear diameter (with chain) Minimum 61.0 mm (2.40 in.)
No. 1 idle gear Gear diameter (with chain) Minimum 61.0 mm (2.40 in.)
Oil clearance Standard idle gear shaft diameter 22.987 to 23.000 mm (0.905 to 0.906 in.)
Standard idle gear inside diameter 23.02 to 23.03 mm (0.906 to 0.907 in.)
Standard oil clearance 0.020 to 0.043 mm (0.000787 to 0.00169 in.)
Maximum oil clearance 0.093 mm (0.00366 in.)
No. 2 chain tensioner Depth Maximum 1.0 mm (0.0394 in.)
No. 3 chain tensioner 1.0 mm (0.0394 in.)
Chain tensioner slipper 1.0 mm (0.0394 in.)
No. 1 chain vibration damper 1.0 mm (0.0394 in.)
No. 2 chain vibration damper 1.0 mm (0.0394 in.)
Camshaft thrust clearance (for bank 1) Intake side Standard 0.04 to 0.09 mm (0.00157 to 0.00354 in.)
Maximum 0.11 mm (0.00433 in.)
Exhaust side Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
Camshaft thrust clearance (for bank 2) Intake side Standard 0.05 to 0.10 mm (0.00197 to 0.00394 in.)
Maximum 0.12 mm (0.00472 in.)
Exhaust side Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
Camshaft oil clearance (for bank 1) No. 1 journal Intake side Standard 0.028 to 0.048 mm (0.00110 to 0.00189 in.)
Maximum 0.07 mm (0.00276 in.)
Exhaust side Standard 0.040 to 0.079 mm (0.00157 to 0.00311 in.)
Maximum 0.10 mm (0.00394 in.)
Other journal Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.10 mm (0.00394 in.)
Camshaft oil clearance (for bank 2) No. 1 journal Intake side Standard 0.050 to 0.089 mm (0.00197 to 0.00350 in.)
Maximum 0.08 mm (0.00315 in.)
Exhaust side Standard 0.040 to 0.079 mm (0.00157 to 0.00311 in.)
Maximum 0.10 mm (0.00394 in.)
Other journal Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.10 mm (0.00394 in.)
Exhaust manifold Warpage 0.70 mm (0.0276 in.)
Intake manifold Intake air surge tank side Warpage Maximum 0.80 mm (0.0315 in.)
Cylinder head side 0.20 mm (0.00787 in.)
CYLINDER HEAD
Cylinder head warpage Cylinder block side Standard 0.05 mm (0.00197 in.)
Intake manifold side 0.08 mm (0.00315 in.)
Exhaust manifold side 0.05 mm (0.00197 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 106.95 mm (4.21 in.)
Minimum 106.40 mm (4.19 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 105.80 mm (4.17 in.)
Minimum 105.30 mm (4.15 in.)
Valve guide bush Inside diameter Standard 5.51 to 5.53 mm (0.217 to 0.218 in.)
Valve guide bush oil clearance Intake Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.08 mm (0.00315 in.)
Exhaust Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.10 mm (0.00394 in.)
Compression spring Free length Standard 47.8 mm (1.88 in.)
Deviation Maximum 2.0 mm (0.0787 in.)
Installed tension Standard 186 to 206 N (19 to 21 kgf, 41.8 to 46.3 lbf) at 36.2 mm (1.43 in.)
Valve lifter Valve lifter diameter Standard 30.966 to 30.976 mm (1.219 to 1.220 in.)
Lifter bore diameter Standard 31.009 to 31.025 mm (1.220 to 1.221 in.)
Oil clearance Standard 0.033 to 0.059 mm (0.00130 to 0.00232 in.)
Maximum 0.08 mm (0.00315 in.)
Valve guide bush Cylinder bore diameter STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Bush bore diameter STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Protrusion height Standard 9.3 to 9.7 mm (0.366 to 0.382 in.)
Bush length Intake Standard 34.3 to 34.7 mm (1.35 to 1.37 in.)
Exhaust 40.3 to 40.7 mm (1.59 to 1.60 in.)
CYLINDER BLOCK
Connecting rod Thrust clearance Standard 0.15 to 0.30 mm (0.00591 to 0.0118 in.)
Maximum 0.35 mm (0.0138 in.)
Thickness Standard 20.80 to 20.85 mm (0.819 to 0.821 in.)
Oil clearance Standard 0.040 to 0.066 mm (0.00157 to 0.00260 in.)
Maximum 0.086 mm (0.00339 in.)
Standard sized bearing 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 0.05900 in.)
Bend 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 pin Diameter Standard 55.992 to 56.000 mm (2.2044 to 2.2047 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 1.93 to 1.98 mm (0.0760 to 0.0780 in.)
Circle runout Maximum 0.06 mm (0.00236 in.)
Main journal Diameter Standard 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crank pin Diameter Standard 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Cylinder block Warpage Maximum 0.05 mm (0.00197 in.)
Cylinder bore Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum 94.132 mm (3.7060 in.)
Piston ring Groove clearance No. 1 0.02 to 0.07 mm (0.000787 to 0.00276 in.)
No. 2 0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Oil 0.07 to 0.15 mm (0.00276 to 0.00590 in.)
End gap Standard No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2 0.40 to 0.50 mm (0.0157 to 0.0197 in.)
Oil 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
Maximum No. 1 1.0 mm (0.0394 in.)
No. 2 1.1 mm (0.0433 in.)
Oil 1.0 mm (0.0394 in.)
Piston Diameter Reference piston diameter (new part) 93.926 to 93.936 mm (3.6979 to 3.6983 in.)
Oil clearance Reference oil clearance (new part) 0.064 to 0.086 mm (0.00252 to 0.00339 in.)
Maximum 0.13 mm (0.00512 in.)
Piston pin Hole inside diameter Mark A 22.001 to 22.004 mm (0.86618 to 0.86630 in.)
Mark B 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
Mark C 22.008 to 22.010 mm (0.86645 to 0.86653 in.)
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 0.86642 in.)
Connecting rod bush 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.)
Piston pin hole oil clearance Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum 0.040 mm (0.00157 in.)
Bush inside oil clearance Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.050 mm (0.00197 in.)
Connecting rod bolt Diameter Standard 7.2 to 7.3 mm (0.283 to 0.287 in.)
Maximum 7.0 mm (0.276 in.)
Crankshaft bearing cap set bolt Diameter Standard 10.0 to 10.2 mm (0.394 to 0.402 in.)
Crankshaft Oil clearance Standard 0.018 to 0.030 mm (0.000709 to 0.00118 in.)
Maximum 0.046 mm (0.00181 in.)
Cylinder Block Main Journal Bore Diameter (A) Mark 00 77.000 mm (3.03149 in.)
Mark 01 77.001 mm (3.03152 in.)
Mark 02 77.002 mm (3.03156 in.)
Mark 03 77.003 mm (3.03160 in.)
Mark 04 77.004 mm (3.03164 in.)
Mark 05 77.005 mm (3.03168 in.)
Mark 06 77.006 mm (3.03172 in.)
Mark 07 77.007 mm (3.03176 in.)
Mark 08 77.008 mm (3.03180 in.)
Mark 09 77.009 mm (3.03184 in.)
Mark 10 77.010 mm (3.03188 in.)
Mark 11 77.011 mm (3.03192 in.)
Mark 12 77.012 mm (3.03196 in.)
Mark 13 77.013 mm (3.03200 in.)
Mark 14 77.014 mm (3.03204 in.)
Mark 15 77.015 mm (3.03208 in.)
Mark 16 77.016 mm (3.03211 in.)
Crankshaft Main Journal Diameter (B) Mark 00 71.999 to 72.000 mm (2.83460 to 2.83464 in.)
Mark 01 71.998 to 71.999 mm (2.83456 to 2.83460 in.)
Mark 02 71.997 to 71.998 mm (2.83452 to 2.83456 in.)
Mark 03 71.996 to 71.997 mm (2.83448 to 2.83452 in.)
Mark 04 71.995 to 71.996 mm (2.83440 to 2.83448 in.)
Mark 05 71.994 to 71.995 mm (2.83440 to 2.83444 in.)
Mark 06 71.993 to 71.994 mm (2.83436 to 2.83440 in.)
Mark 07 71.992 to 71.993 mm (2.83432 to 2.83436 in.)
Mark 08 71.991 to 71.992 mm (2.83428 to 2.83432 in.)
Mark 09 71.990 to 71.991 mm (2.83424 to 2.83428 in.)
Mark 10 71.989 to 71.990 mm (2.83420 to 2.83424 in.)
Mark 11 71.988 to 71.989 mm (2.83416 to 2.83420 in.)
Standard Bearing Center Wall Thickness Mark 1 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
Mark 2 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
Mark 3 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
Mark 4 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
Mark 5 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
Crankshaft bearing Bearing cap's edge and the lower bearing's edge Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)
Connecting rod bearing connecting rod's and bearing cap's edges Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)