2AR-FE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminals TC and CG of DLC3 connected

8 to 12° BTDC at idle

(Transaxle in neutral)

Terminals TC and CG of DLC3 disconnected

5 to 15° BTDC at idle

(Transaxle in neutral)

Engine idle speed

610 to 710 rpm

(Transaxle in neutral)

Compression Standard pressure

1450 kPa (14.8 kgf/cm2, 210 psi)

Minimum pressure

980 kPa (10.0 kgf/cm2, 142 psi)

Difference between each cylinder

100 kPa (1.0 kgf/cm2, 15 psi)

ENGINE UNIT
Camshaft Circle runout Maximum 0.03 mm (0.00118 in.)
Journal diameter No. 1 journal Standard 34.449 to 34.465 mm (1.356 to 1.357 in.)
Other journals Standard 22.959 to 22.975 mm (0.904 to 0.905 in.)
Cam lobe height Intake Standard 44.163 to 44.305 mm (1.739 to 1.744 in.)
Minimum 44.013 mm (1.733 in.)
Exhaust Standard 44.144 to 44.286 mm (1.738 to 1.744 in.)
Minimum 43.996 mm (1.732 in.)
Chain sub-assembly Elongation Maximum 137.7 mm (5.42 in.)
Crankshaft timing sprocket Diameter (with chain) Minimum 59.94 mm (2.36 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.)
Timing chain guide Worn depth Maximum 1.0 mm (0.0394 in.)
Engine balancer assembly Crankshaft backlash Standard 0.05 to 0.20 mm (0.00197 to 0.00787 in.)
Maximum 0.20 mm (0.00787 in.)
Thrust clearance No. 1 balance shaft Standard 0.05 to 0.09 mm (0.00197 to 0.00354 in.)
Maximum 0.09 mm (0.00354 in.)
No. 2 balance shaft Standard 0.05 to 0.09 mm (0.00197 to 0.00354 in.)
Maximum 0.09 mm (0.00354 in.)
Backlash Standard 0.04 to 0.17 mm (0.00157 to 0.00669 in.)
Maximum 0.17 mm (0.00669 in.)
Cylinder head bolt Measurement point 106 mm (4.17 in.)
Diameter Standard 10.85 to 11.00 mm (0.427 to 0.433 in.)
Minimum 10.6 mm (0.417 in.)
Exhaust manifold converter sub-assembly Warpage Maximum 0.7 mm (0.0276 in.)
Stiffening crankcase ring pin Protrusion height Standard 4.3 to 5.3 mm (0.169 to 0.209 in.)
Camshaft bearing cap setting ring pin Protrusion height Standard 2.7 to 3.3 mm (0.106 to 0.130 in.)
Camshaft housing straight pin Protrusion height Standard 5.0 to 7.0 mm (0.197 to 0.276 in.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Cylinder head lower 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.)
Compression spring Free length Wire diameter 3.3 mm (0.130 in.) Standard 49.0 to 51.0 mm (1.93 to 2.01 in.)
Wire diameter 3.4 mm (0.134 in.) Standard 47.2 to 49.2 mm (1.86 to 1.94 in.)
Deviation Maximum 1.0 mm (0.0394 in.)
Angle Maximum
Intake valve Valve stem diameter 5.470 to 5.485 mm (0.21535 to 0.21594 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.50 mm (0.0197 in.)
Overall length Standard 103.92 mm (4.09 in.)
Minimum 103.42 mm (4.07 in.)
Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.21516 to 0.21575 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Minimum 0.50 mm (0.0197 in.)
Overall length Standard 112.91 mm (4.45 in.)
Minimum 112.41 mm (4.43 in.)
Valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 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 (0.00394 in.)

Bush bore diameter

(Cylinder head side)

Standard 10.285 to 10.306 mm (0.405 to 0.406 in.)
Valve guide bush 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.)
Bush length Intake Standard 41.3 to 41.7 mm (1.626 to 1.642 in.)
Exhaust Standard 46.8 to 47.2 mm (1.843 to 1.858 in.)
Protrusion height Intake Standard 14.8 to 15.2 mm (0.583 to 0.598 in.)
Exhaust Standard 14.2 to 14.6 mm (0.559 to 0.575 in.)
Camshaft Oil clearance Intake No. 1 journal Standard 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum 0.085 mm (0.00335 in.)
Exhaust No. 1 journal Standard 0.049 to 0.086 mm (0.00193 to 0.00339 in.)
Maximum 0.095 mm (0.00374 in.)
Other journal Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.085 mm (0.00335 in.)
Thrust clearance Standard 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum 0.170 mm (0.00669 in.)
Spark plug tube Protrusion height Standard 112 mm (4.41 in.)
Ring pin Protrusion height Standard 6.5 to 7.5 mm (0.256 to 0.295 in.)
CYLINDER BLOCK
Connecting rod thrust clearance Standard 0.160 to 0.512 mm (0.00630 to 0.0202 in.)
Maximum 0.512 mm (0.0202 in.)
Connecting rod oil clearance Standard 0.030 to 0.063 mm (0.00118 to 0.00248 in.)
Maximum 0.07 mm (0.00276 in.)
Standard connecting rod big end inside diameter Mark 1 54.500 to 54.508 mm (2.1457 to 2.1460 in.)
Mark 2 54.509 to 54.516 mm (2.1460 to 2.1463 in.)
Mark 3 54.517 to 54.524 mm (2.1463 to 2.1466 in.)
Standard connecting rod bearing center wall thickness Mark 1 1.483 to 1.487 mm (0.0584 to 0.0585 in.)
Mark 2 1.488 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
Crankshaft thrust clearance Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Maximum 0.30 mm (0.0118 in.)
Crankshaft thrust washer thickness Standard 1.93 to 1.98 mm (0.0760 to 0.0780 in.)
Cylinder block sub-assembly Warpage Maximum 0.05 mm (0.00197 in.)
Cylinder bore Standard 90.000 to 90.013 mm (3.543 to 3.544 in.)
Maximum 90.13 mm (3.548 in.)
Piston diameter Standard 89.985 to 89.995 mm (3.5427 to 3.5431 in.)
Piston oil clearance Standard 0.010 to 0.033 mm (0.000394 to 0.00130 in.)
Maximum 0.10 mm (0.00394 in.)
Standard 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.)
Standard piston ring groove clearance No. 1 ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
Oil ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
Piston ring end gap Standard No. 1 ring 0.22 to 0.27 mm (0.00866 to 0.0106 in.)
No. 2 ring 0.37 to 0.42 mm (0.0146 to 0.0165 in.)
Oil ring 0.10 to 0.20 mm (0.00394 to 0.00787 in.)
Maximum No. 1 ring 0.87 mm (0.0343 in.)
No. 2 ring 1.02 mm (0.0402 in.)
Oil ring 0.80 mm (0.0315 in.)
Standard 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

(Piston side)

Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum 0.013 mm (0.000512 in.)

Piston pin oil clearance

(Connecting rod side)

Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.017 mm (0.000669 in.)
Connecting rod sub-assembly 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.)
Standard connecting rod small end 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.)
Crankshaft Circle runout Maximum 0.003 mm (0.000118 in.)
Main journal diameter Standard 54.988 to 55.000 mm (2.1649 to 2.1654 in.)
Main journal taper and out-of-round Maximum 0.003 mm (0.000118 in.)
Crank pin diameter Standard 51.492 to 51.500 mm (2.027 to 2.028 in.)
Crank pin taper and out-of-round Maximum 0.003 mm (0.000118 in.)
Oil clearance Standard 0.017 to 0.040 mm (0.000669 to 0.00157 in.)
Maximum 0.05 mm (0.00197 in.)
Standard cylinder block journal inside diameter Mark 0 59.000 to 59.002 mm (2.32283 to 2.32291 in.)
Mark 1 59.003 to 59.004 mm (2.32295 to 2.32299 in.)
Mark 2 59.005 to 59.006 mm (2.32303 to 2.32307 in.)
Mark 3 59.007 to 59.009 mm (2.32311 to 2.32318 in.)
Mark 4 59.010 to 59.011 mm (2.32322 to 2.32326 in.)
Mark 5 59.012 to 59.013 mm (2.32330 to 2.32334 in.)
Mark 6 59.014 to 59.016 mm (2.32338 to 2.32346 in.)
Standard crankshaft main journal diameter Mark 0 54.999 to 55.000 mm (2.16531 to 2.16535 in.)
Mark 1 54.997 to 54.998 mm (2.16523 to 2.16527 in.)
Mark 2 54.995 to 54.996 mm (2.16515 to 2.16519 in.)
Mark 3 54.993 to 54.994 mm (2.16507 to 2.16511 in.)
Mark 4 54.991 to 54.992 mm (2.16500 to 2.16504 in.)
Mark 5 54.988 to 54.990 mm (2.16488 to 2.16496 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.)
Crankshaft bearing cap bolt Measurement point 58.5 mm (2.30 in.)
Diameter Standard 9.77 to 9.96 mm (0.385 to 0.392 in.)
Minimum 9.1 mm (0.358 in.)
Connecting rod bolt Diameter Standard 8.5 to 8.6 mm (0.335 to 0.339 in.)
Minimum 8.3 mm (0.327 in.)
Ring pin Protrusion height Pin A 5.0 to 7.0 mm (0.197 to 0.276 in.)
Pin B 4.0 to 7.0 mm (0.157 to 0.276 in.)
Straight pin Protrusion height Pin A 11.0 to 13.0 mm (0.433 to 0.512 in.)
Pin B 5.0 to 7.0 mm (0.197 to 0.276 in.)