2TR-FE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Standard 2 to 15° BTDC @ idle
with Terminal TC and CG connected of DLC3 3 to 7° BTDC @ idle
Idle speed Standard 600 to 700 rpm
Compression Compression pressure Standard

1230 kPa (12.5 kgf/cm2, 178 psi) or higher
Minimum

880 kPa (9.0 kgf/cm2, 128 psi)
Difference between each cylinder

68 kPa (0.7 kgf/cm2, 9.9 psi) or less
ENGINE UNIT
Chain sub-assembly Chain elongation Maximum 147.5 mm (5.81 in.)
No. 2 chain sub-assembly Chain elongation Maximum 123.6 mm (4.87 in.)
Camshaft timing gear assembly Distance Minimum 1.0 mm (0.0394 in.)
Sprocket diameter (with chain) Minimum 113.8 mm (4.48 in.)
Crankshaft timing exhaust gear assembly Distance Minimum 1.0 mm (0.0394 in.)
Sprocket diameter (with chain) Minimum 113.8 mm (4.48 in.)
Camshaft timing gear or sprocket Distance Minimum 1.0 mm (0.0394 in.)
Sprocket diameter (with chain) Minimum 59.4 mm (2.34 in.)
Chain tensioner slipper Depth Maximum 2.0 mm (0.0787 in.)
No. 1 chain vibration damper Depth Maximum 2.0 mm (0.0787 in.)
Timing chain guide Depth Maximum 0.5 mm (0.0197 in.)
No. 2 crankshaft timing sprocket Sprocket diameter (with chain) Minimum 96.7 mm (3.81 in.)
Balance shaft drive gear sub-assembly Sprocket diameter (with No. 2 chain sub-assembly) Minimum 75.9 mm (2.99 in.)
No. 2 chain vibration damper Depth Maximum 1.0 mm (0.0394 in.)
No. 3 chain vibration damper Depth Maximum 1.0 mm (0.0394 in.)
No. 4 chain vibration damper Depth Maximum 1.0 mm (0.0394 in.)
Cylinder head set bolt Outside diameter Standard 10.76 to 10.97 mm (0.424 to 0.432 in.)
Minimum 10.40 mm (0.409 in.)
Distance 30 mm (1.18 in.)
Camshaft Circle runout Maximum 0.03 mm ( 0.00118 in.)
Cam lobe height Standard 42.855 to 42.955 mm (1.687 to 1.691 in.)
Minimum 42.855 mm (1.687 in.)
Journal diameter No. 1 journal Standard 35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal Standard 26.959 to 26.975 mm (1.061 to 1.062 in.)
No. 2 camshaft Circle runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height Standard 42.854 to 42.954 mm (1.687 to 1.691 in.)
Minimum 42.854 mm (1.687 in.)
Journal diameter No. 1 journal Standard 35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal Standard 26.959 to 26.975 mm (1.061 to 1.062 in.)
Exhaust manifold Warpage Maximum 0.7 mm (0.0276 in.)
CYLINDER HEAD
Cylinder head Warpage Maximum 0.05 mm (0.00197 in.)
Inner compression spring free length Standard 52.13 mm (2.05 in.)
Deviation Maximum 1.3 mm (0.0512 in.)
Angle Maximum 2°
Intake valve Overall length Standard 106.26 mm (4.18 in.)
Minimum 105.96 mm (4.17 in.)
Valve stem diameter Standard 5.470 to 5.485 mm (0.215 to 0.216 in.)
Margin thickness Standard 1.05 to 1.45 mm (0.0413 to 0.0571 in.)
Minimum 0.50 mm (0.0197 in.)
Exhaust valve Overall length Standard 106.74 mm (4.20 in.)
Minimum 106.44 mm (4.19 in.)
Valve stem diameter Standard 5.465 to 5.480 mm (0.215 to 0.216 in.)
Margin thickness Standard 1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Minimum 0.50 mm (0.0197 in.)
Camshaft thrust clearance Thrust clearance Standard 0.10 to 0.24 mm (0.00394 to 0.00945 in.)
Maximum 0.26 mm (0.0102 in.)
Camshaft oil clearance Oil clearance No. 1 journal Standard 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Other journal Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.08 mm (0.00315 in.)
Valve guide bush oil clearance Bush inside diameter Standard 5.51 to 5.53 mm (0.217 to 0.218 in.)
Oil clearance Intake Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.08 mm (0.00315 in.)
Exhaust Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.10 mm (0.00397 in.)
Intake valve guide bush Bush bore diameter STD Standard 10.285 to 10.306 mm (0.405 to 0.406 in.)
O/S 0.05 Standard 10.335 to 10.356 mm (0.407 to 0.408 in.)
Protrusion height Standard 9.8 to 10.2 mm (0.386 to 0.402 in.)
Exhaust valve guide bush Bush bore diameter STD Standard 10.285 to 10.306 mm (0.405 to 0.406 in.)
O/S 0.05 Standard 10.335 to 10.356 mm (0.407 to 0.408 in.)
Protrusion height Standard 7.6 to 8.0 mm (0.299 to 0.315 in.)
Intake valve seat Width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 in.)
Exhaust valve seat Width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 in.)
CYLINDER BLOCK
Connecting rod thrust clearance Standard 0.15 to 0.35 mm (0.00591 to 0.0138 in.)
Maximum 0.40 mm (0.0157 in.)
Connecting rod oil clearance Oil clearance Standard 0.039 to 0.066 mm (0.00154 to 0.00260 in.)
Maximum 0.066 mm (0.00260 in.)
Crankshaft pin diameter Standard 52.989 to 53.002 mm (2.086 to 2.087 in.)
Bearing center wall thickness Mark 4 Standard 1.487 to 1.490 mm (0.05854 to 0.05866 in.)
Mark 5 Standard 1.491 to 1.493 mm (0.05870 to 0.05878 in.)
Mark 6 Standard 1.494 to 1.496 mm (0.05882 to 0.05890 in.)
Crankshaft thrust clearance Thrust clearance Standard 0.02 to 0.22 mm (0.000787 to 0.00866 in.)
Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness 2.440 to 2.490 mm (0.0961 to 0.0980 in.)
Balanceshaft thrust clearance Thrust clearance Standard 0.07 to 0.13 mm (0.00276 to 0.00512 in.)
Maximum 0.20 mm (0.00787 in.)
Cylinder block for warpage Warpage Maximum 0.05 mm (0.00197 in.)
Cylinder bore Reference value (new parts) Standard 94.990 to 95.003 mm (3.7398 to 3.7403 in.)
Piston diameter Reference value (new parts) Standard 94.971 to 94.981 mm (3.7390 to 3.7394 in.)
Piston oil clearance Reference value (new parts) Standard 0.009 to 0.048 mm (0.000354 to 0.00189 in.)
Piston ring Ring groove clearance No. 1 compression ring Standard 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 compression ring Standard 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
Oil ring Standard 0.060 to 0.120 mm (0.00236 to 0.00472 in.)
End gap No. 1 compression ring Standard 0.30 to 0.35 mm (0.0118 to 0.0138 in.)
Maximum 0.90 mm (0.0354 in.)
No. 2 compression ring Standard 0.59 to 0.71 mm (0.0232 to 0.0280 in.)
Maximum 1.36 mm (0.0535 in.)
Oil ring Standard 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum 0.75 mm (0.0295 in.)
Piston pin Piston pin hole inside diameter Item A Standard 22.001 to 22.004 mm (0.86618 to 0.86630 in.)
Item B Standard 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
Item C Standard 22.008 to 22.010 mm (0.86645 to 0.86653 in.)
Piston pin diameter Item A Standard 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
Item B Standard 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
Item C Standard 22.004 to 22.006 mm (0.86630 to 0.86638 in.)
Oil clearance Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum 0.010 mm (0.000394 in.)
Bush inside diameter Item A Standard 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
Item B Standard 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
Item C Standard 22.012 to 22.014 mm (0.86661 to 0.86669 in.)
Connecting rod Bend Maximum 0.03 mm (0.00118 in.) per 100 mm (3.94 in.)
Twist Maximum 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
Crankshaft Circle runout Maximum 0.03 mm (0.00118 in.)
Main journal diameter No. 3 journal Standard 59.981 to 59.994 mm (2.3615 to 2.3620 in.)
Except No. 3 journal Standard 59.987 to 60.000 mm (2.3617 to 2.3622 in.)
Crank pin diameter Standard 52.989 to 53.002 mm (2.086 to 2.087 in.)
Crankshaft oil clearance Oil clearance Standard 0.030 to 0.044 mm (0.00118 to 0.00173 in.)
Standard 0.024 to 0.038 mm (0.000945 to 0.00150 in.)
Maximum 0.10 mm (0.00394 in.)
Cylinder block main journal bore diameter Mark A Reference 64.004 to 64.006 mm (2.51984 to 2.51992 in.)
Mark B Reference 64.007 to 64.008 mm (2.51996 to 2.51999 in.)
Mark C Reference 64.009 to 64.010 mm (2.52003 to 2.52007 in.)
Mark D Reference 64.011 to 64.012 mm (2.52011 to 2.52015 in.)
Mark E Reference 64.013 to 64.014 mm (2.52019 to 2.52023 in.)
Mark F Reference 64.015 to 64.016 mm (2.52027 to 2.52031 in.)
Mark G Reference 64.017 to 64.018 mm (2.52035 to 2.52039 in.)
Mark H Reference 64.019 to 64.020 mm (2.52043 to 2.52047 in.)
Mark J Reference 64.021 to 64.022 mm (2.52051 to 2.52055 in.)
Crankshaft journal bore diameter No. 3 journal Mark 3 Reference 59.993 to 59.994 mm (2.36192 to 2.36196 in.)
Mark 4 Reference 59.991 to 59.992 mm (2.36185 to 2.36189 in.)
Mark 5 Reference 59.989 to 59.990 mm (2.36177 to 2.36181 in.)
Mark 6 Reference 59.987 to 59.988 mm (2.36169 to 2.36173 in.)
Mark 7 Reference 59.985 to 59.986 mm (2.36161 to 2.36165 in.)
Mark 8 Reference 59.983 to 59.984 mm (2.36153 to 2.36157 in.)
Mark 9 Reference 59.981 to 59.982 mm (2.36145 to 2.36149 in.)
Other journal Mark 0 Reference 59.999 to 60.000 mm (2.36216 to 2.36220 in.)
Mark 1 Reference 59.997 to 59.998 mm (2.36208 to 2.36212 in.)
Mark 2 Reference 59.995 to 59.996 mm (2.36200 to 2.36204 in.)
Mark 3 Reference 59.993 to 59.994 mm (2.36192 to 2.36196 in.)
Mark 4 Reference 59.991 to 59.992 mm (2.36185 to 2.36189 in.)
Mark 5 Reference 59.989 to 59.990 mm (2.36177 to 2.36181 in.)
Mark 6 Reference 59.987 to 59.988 mm (2.36169 to 2.36173 in.)
Bearing center wall thickness Mark 1 Reference 1.987 to 1.990 mm (0.07823 to 0.07835 in.)
Mark 2 Reference 1.991 to 1.993 mm (0.7839 to 0.07846 in.)
Mark 3 Reference 1.994 to 1.996 mm (0.07850 to 0.07858 in.)
Mark 4 Reference 1.997 to 1.999 mm (0.07862 to 0.07870 in.)
Mark 5 Reference 2.000 to 2.002 mm (0.07874 to 0.07882 in.)
No. 1 balanceshaft Journal diameter Item A Standard 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
Item B Standard 37.449 to 37.465 mm (1.4744 to 1.4750 in.)
Bearing inside diameter Item A Standard 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
Item B Standard 37.525 to 37.545 mm (1.4774 to 1.4781 in.)
Oil clearance Item A Standard 0.040 to 0.076 mm (0.00157 to 0.00299 in.)
Item B Standard 0.060 to 0.096 mm (0.00236 to 0.00378 in.)
Maximum 0.15 mm (0.00591 in.)
No. 2 balanceshaft Journal diameter Item A Standard 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
Item B Standard 37.449 to 37.465 mm (1.4744 to 1.4750 in.)
Bearing inside diameter Item A Standard 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
Item B Standard 37.525 to 37.545 mm (1.4774 to 1.4781 in.)
Oil clearance Item A Standard 0.040 to 0.076 mm (0.00157 to 0.00299 in.)
Item B Standard 0.060 to 0.096 mm (0.00236 to 0.00378 in.)
Maximum 0.15 mm (0.00591 in.)
Crankshaft bearing cap set bolt Diameter Standard 10.76 to 10.97 mm (0.424 to 0.432 in.)
Minimum 10.66 mm (0.420 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.)
Bore cylinder Piston diameter (O/S 0.50) Standard 95.471 to 95.481 mm (3.7587 to 3.7591 in.)