2GR-FE ENGINE MECHANICAL SERVICE DATA

Ignition timing Terminals TC and CG of DLC3 connected 8 to 12° BTDC at idle (Transmission in neutral)
Terminals TC and CG of DLC3 disconnected 9.5 to 24.5° BTDC at idle (Transmission in neutral)
Idle speed 600 to 700 rpm (Transmission in neutral)
Compression Standard

1.3 MPa (13 kgf/cm2, 189 psi)
Minimum

0.98 MPa (10 kgf/cm2, 142 psi)
Difference

0.1 MPa (1.0 kgf/cm2, 15 psi)
Intake manifold Cylinder head side Maximum 0.1 mm (0.00394 in.)
Surge tank side Maximum 0.1 mm (0.00394 in.)
Exhaust manifold sub-assembly LH Maximum 0.7 mm (0.0276 in.)
RH Maximum 0.7 mm (0.0276 in.)
Cylinder head set bolt

Outside diameter

(Measuring point (distance from the seat): 103 mm (4.06 in.))

 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) Minimum 61.4 mm (2.418 in.)
Idle sprocket assembly Diameter (with chain) Minimum 61.4 mm (2.418 in.)
Idle gear shaft Idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.)
Idle gear inside diameter 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 Worn depth Maximum 0.9 mm (0.0354 in.)
No. 3 chain tensioner assembly Worn depth Maximum 0.9 mm (0.0354 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.)
No. 2 chain vibration damper Worn depth Maximum 1.0 mm (0.0394 in.)
Cylinder head sub-assembly Warpage Cylinder head lower Standard 0.05 mm (0.00197 in.)
Maximum 0.10 mm (0.00394 in.)
Intake Standard 0.08 mm (0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Exhaust Standard 0.08 mm (0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Intake valve Valve stem diameter 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 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 45.91 mm (1.8075 in.)
Deviation Maximum 1.0 mm (0.0394 in.)
Angle (reference) Maximum 2°
Intake valve guide bush Inside diameter 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 9.30 to 9.70 mm (0.3661 to 0.3819 in.)
Exhaust valve guide bush Inside diameter 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 9.30 to 9.70 mm (0.3661 to 0.3819 in.)
Camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Standard 44.316 to 44.416 mm (1.7448 to 1.7486 in.)
Minimum 44.166 mm (1.7388 in.)
Oil clearance No. 1 journal Standard 0.032 to 0.071 mm (0.00126 to 0.00280 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.)
Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
No. 2 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Standard 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Minimum 44.112 mm (1.7366 in.)
Oil clearance No. 1 journal Standard 0.032 to 0.071 mm (0.00126 to 0.00280 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.)
Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
No. 3 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Standard 44.316 to 44.416 mm (1.7448 to 1.7486 in.)
Minimum 44.166 mm (1.7388 in.)
Oil clearance No. 1 journal Standard 0.032 to 0.071 mm (0.00126 to 0.00280 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.)
Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
No. 4 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.)
Circuit runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Standard 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Minimum 44.112 mm (1.7366 in.)
Oil clearance No. 1 journal Standard 0.032 to 0.071 mm (0.00126 to 0.00280 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.)
Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.15 mm (0.00591 in.)
Ring pin for cylinder head sub-assembly Protrusion height 2.5 to 3.5 mm (0.0984 to 0.138 in.)
Straight pin for cylinder head sub-assembly Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)
Spark plug tube Protrusion height 72.9 mm (2.87 in.)
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.)
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.)
Cylinder block warpage Maximum 0.07 mm (0.00276 in.)
Cylinder bore diameter Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum 94.13 mm (3.7059 in.)
Piston diameter Distance 8.9 mm (0.3504 in.)
Standard 93.960 to 93.980 mm (3.6992 to 3.7000 in.)
Minimum 93.830 mm (3.6941 in.)
Piston oil clearance Standard 0.020 to 0.052 mm (0.000787 to 0.00205 in.)
Maximum 0.060 mm (0.00236 in.)
Connecting rod out-of alignment 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.)
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 (for Piston) 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.)
Piston pin oil clearance (for Connecting rod) Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.030 mm (0.00118 in.)
Piston ring groove clearance No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
Oil 0.070 to 0.150 mm (0.00276 to 0.00591 in.)
Piston ring end gap No. 1 Standard 0.22 to 0.32 mm (0.00866 to 0.0126 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 Standard 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Maximum 0.85 mm (0.0335 in.)
Oil (Side rail) Standard 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
Maximum 0.60 mm (0.0236 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 bearing cap set bolt

Diameter

(Measuring point: 40 mm (1.57 in.))

 Standard 10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Maximum 10.7 mm (0.4213 in.)
Crankshaft circle runout Maximum 0.06 mm (0.00236 in.)
Main journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
Main journal taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
Crank pin 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.)
Straight pin for cylinder block sub-assembly Protrusion height Pin A 23 mm (0.906 in.)
Pin B 6.0 mm (0.236 in.)
Pin C 11 mm (0.433 in.)
Pin D 9.0 mm (0.354 in.)