2TR-FE ENGINE MECHANICAL SERVICE DATA

Ignition timing 3 to 7° BTDC at idle
Idle speed 600 to 700 rpm
CO Idle CO concentration 0 to 0.5%
HC Idle HC concentration Applicable local regulation
Compression Compression pressure

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

Minimum pressure

880 kPa (9.0 kgf*cm2, 128 psi)

Difference between each cylinder

68 kPa (0.7 kgf*cm2, 10 psi) or less

No. 1 camshaft Maximum circle runout 0.03 mm (0.0012 in.)
Standard cam robe height 42.855 to 42.955 mm (1.6872 to 1.6911 in.)
Minimum cam robe height 42.855 mm (1.6872 in.)
No. 1 journal diameter 35.949 to 35.965 mm (1.4153 to 1.4159 in.)
Other journal diameter 26.959 to 26.975 mm (1.0614 to 1.0620 in.)
Standard thrust clearance 0.10 to 0.24 mm (0.004 to 0.009 in.)
Maximum thrust clearance 0.26 mm (0.010 in.)

Standard oil clearance

: No. 1 journal

0.035 to 0.072 mm (0.0014 to 0.0029 in.)

Standard oil clearance

: Other journal

0.025 to 0.062 mm (0.0010 to 0.0028 in.)
Maximum oil clearance 0.08 mm (0.0031 in.)
No. 2 camshaft Maximum circle runout 0.03 mm (0.0012 in.)
Standard cam robe height 42.854 to 42.954 mm (1.687 to 1.6911 in.)
Minimum cam robe height 42.854 mm (1.6872 in.)
No. 1 journal diameter 35.949 to 35.965 mm (1.4153 to 1.4159 in.)
Other journal diameter 26.959 to 26.975 mm (1.0614 to 1.0620 in.)
Standard thrust clearance 0.10 to 0.24 mm (0.004 to 0.009 in.)
Maximum thrust clearance 0.26 mm (0.010 in.)

Standard oil clearance

: No. 1 journal

0.035 to 0.072 mm (0.0014 to 0.0029 in.)

Standard oil clearance

: Other journal

0.025 to 0.062 mm (0.0010 to 0.0028 in.)
Maximum oil clearance 0.08 mm (0.0031 in.)
Chain Maximum chain elongation 147.5 mm (5.807 in.)
No. 2 chain Maximum chain elongation 123.6 mm (4.866 in.)
Camshaft timing sprocket Minimum distance 1.0 mm (0.039 in.)
Minimum sprocket diameter (with chain) 113.8 mm (4.480 in.)
Camshaft timing gear Minimum distance 1.0 mm (0.039 in.)
Minimum sprocket diameter (with chain) 113.8 mm (4.480 in.)
Crankshaft timing sprocket Minimum distance 1.0 mm (0.039 in.)
Minimum sprocket diameter (with chain) 59.4 mm (2.358 in.)
Balance shaft drive gear Minimum sprocket diameter (with chain) 75.9 mm (2.988 in.)
No. 2 crankshaft timing sprocket Minimum sprocket diameter (with chain) 96.7 mm (3.807 in.)
Chain tensioner slipper Maximum wear 2.0 mm (0.079 in.)
Chain vibration damper Maximum wear 2.0 mm (0.079 in.)
No. 2 chain vibration damper Maximum wear 1.0 mm (0.039 in.)
No. 3 chain vibration damper Maximum wear 1.0 mm (0.039 in.)
No. 4 chain vibration damper Maximum wear 1.0 mm (0.039 in.)
Timing chain guide Maximum wear 0.5 mm (0.020 in.)
Cylinder head set bolt Standard outside diameter 10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum outside diameter 10.40 mm (0.4094 in.)
Cylinder head Maximum warpage 0.05 mm (0.0020 in.)
Inner compression spring Free length 48.53 mm (1.9106 in.)
Maximum deviation 1.5 mm (0.059 in.)
Maximum angle (reference)
Intake valve Standard overall length 106.26 mm (4.1835 in.)
Minimum overall length 105.96 mm (4.1716 in.)
Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Standard margin thickness 1.05 to 1.45 mm (0.0413 to 0.0571 in.)
Minimum margin thickness 0.5 mm (0.0197 in.)
Exhaust valve Standard overall length 106.74 mm (4.2024 in.)
Minimum overall length 106.44 mm (4.1905 in.)
Valve stem diameter 5.465 to 5.480 mm (0.2151 to 0.2157 in.)
Standard margin thickness 1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Minimum margin thickness 0.5 mm (0.0197 in.)
Intake valve guide bush Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Standard oil clearance 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Maximum oil clearance 0.08 mm (0.0032 in.)
Bush bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Protrusion height 9.8 to 10.2 mm (0.3858 to 0.4016 in.)
Exhaust valve guide bush Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum oil clearance 0.10 mm (0.0039 in.)
Bush bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Protrusion height 7.6 to 8.0 mm (0.2992 to 0.3150 in.)
Connecting rod Standard thrust clearance 0.150 to 0.350 mm (0.0059 to 0.0138 in.)
Maximum thrust clearance 0.4 mm (0.016 in.)
Standard oil clearance 0.039 to 0.066 mm (0.0015 to 0.0026 in.)

Bearing center wall thickness

: Mark 4

1.484 to 1.487 mm (0.0584 to 0.0585 in.)

Bearing center wall thickness

: Mark 5

1.488 to 1.490 mm (0.0586 to 0.0587 in.)

Bearing center wall thickness

: Mark 6

1.491 to 1.493 mm (0.0587 to 0.0588 in.)
Maximum bend 0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
Maximum twist 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

Bushing inside diameter

: Mark A

22.005 to 22.008 mm (0.86633 to 0.86645 in.)

Bushing inside diameter

: Mark B

22.008 to 22.011 mm (0.86645 to 0.86657 in.)

Bushing inside diameter

: Mark C

22.011 to 22.014 mm (0.86657 to 0.86669 in.)
Standard oil clearance 0.001 to 0.007 mm (0.00004 to 0.00028 in.)
Maximum oil clearance 0.010 mm (0.00039 in.)
Crankshaft Standard thrust clearance 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Maximum thrust clearance 0.30 mm (0.0118 in.)
Thrust washer thickness 2.440 to 2.490 mm (0.0961 to 0.0980 in.)

for Type A and B (No. 3 journal):

Standard oil clearance

0.030 to 0.055 mm (0.0012 to 0.0022 in.)

for Type A and B (Other journal):

Standard oil clearance

0.024 to 0.049 mm (0.0009 to 0.0019 in.)

for Type C (No. 3 journal):

Standard oil clearance

0.030 to 0.044 mm (0.00118 to 0.00173 in.)

for Type C (Other journal):

Standard oil clearance

0.024 to 0.038 mm (0.000945 to 0.00150 in.)
Maximum clearance 0.10 mm (0.0039 in.)
Maximum circle runout 0.03 mm (0.0012 in.)
No. 3 journal diameter 59.981 to 59.994 mm (2.3615 to 2.3620 in.)
Except journal diameter 59.987 to 60.000 mm (2.3229 to 2.3622 in.)
Maximum taper and out-of-round (Main journal) 0.005 mm (0.0002 in.)
Crank pin diameter 52.989 to 53.002 mm (2.0862 to 2.0867 in.)
Maximum taper and out-of-round (Crank pin) 0.003 mm (0.0001 in.)
Crankshaft bearing cap bolt Standard outside diameter 10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum outside diameter 10.66 mm (0.4197 in.)
No. 1 balance shaft Standard thrust clearance 0.07 to 0.13 mm (0.0027 to 0.0051 in.)
Maximum thrust clearance 0.20 mm (0.0079 in.)

Main journal diameter

: A

37.969 to 37.985 mm (1.4948 to 1.4955 in.)

Main journal diameter

: B

37.449 to 37.465 mm (1.4744 to 1.4750 in.)

Bearing inside diameter

: A

38.025 to 38.045 mm (1.4970 to 1.4978 in.)

Bearing inside diameter

: B

37.525 to 37.545 mm (1.4774 to 1.4781 in.)

Standard oil clearance

: A

0.040 to 0.076 mm (0.0016 to 0.0030 in.)

Standard oil clearance

: B

0.060 to 0.096 mm (0.0024 to 0.0038 in.)
Maximum oil clearance 0.15 mm (0.0059 in.)
No. 2 balance shaft Standard thrust clearance 0.07 to 0.13 mm (0.0027 to 0.0051 in.)
Maximum thrust clearance 0.20 mm (0.0079 in.)

Main journal diameter

: A

37.969 to 37.985 mm (1.4948 to 1.4955 in.)

Main journal diameter

: B

37.449 to 37.465 mm (1.4744 to 1.4750 in.)

Bearing inside diameter

: A

38.025 to 38.045 mm (1.4970 to 1.4978 in.)

Bearing inside diameter

: B

37.525 to 37.545 mm (1.4774 to 1.4781 in.)

Standard oil clearance

: A

0.040 to 0.076 mm (0.0016 to 0.0030 in.)

Standard oil clearance

: B

0.060 to 0.096 mm (0.0024 to 0.0038 in.)
Maximum oil clearance 0.15 mm (0.0059 in.)
Cylinder block Maximum warpage 0.05 mm (0.0020 in.)
Standard diameter 94.941 to 94.971 mm (3.7378 to 3.7390 in.)

Piston diameter

: Standard

93.910 to 93.920 mm (3.6972 to 3.6976 in.)

Piston diameter

: O/S 0.50

95.441 to 95.541 mm (3.7575 to 3.7579 in.)
Standard oil clearance 0.019 to 0.052 mm (0.0007 to 0.0020 in.)
Piston pin

Piston pin diameter

: A

21.997 to 22.000 mm (0.86602 to 0.86614 in.)

Piston pin diameter

: B

22.001 to 22.003 mm (0.86615 to 0.86626 in.)

Piston pin diameter

: C

22.003 to 22.006 mm (0.86627 to 0.86638 in.)

Piston pin diameter

: D

22.007 to 22.006 mm (0.86639 to 0.86649 in.)
Piston ring No. 1 Ring groove clearance 0.020 to 0.075 mm (0.0008 to 0.0030 in.)
No. 2 Ring groove clearance 0.020 to 0.065 mm (0.0008 to 0.0026 in.)
Oil Ring groove clearance 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 1 Standard end gap 0.220 to 0.340 mm (0.0087 to 0.0134 in.)
No. 2 Standard end gap 0.450 to 0.570 mm (0.0177 to 0.0224 in.)
Oil (side rail) Standard end gap 0.100 to 0.400 mm (0.0039 to 0.0157 in.)
No. 1 Maximum end gap 0.90 mm (0.0354 in.)
No. 2 Maximum end gap 1.36 mm (0.0535 in.)
Oil (side rail) Maximum end gap 0.75 mm (0.0295 in.)
Connecting rod bolt Standard diameter 7.200 to 7.300 mm (0.283 to 0.287 in.)
Minimum diameter 7.00 mm (0.276 in.)
Connecting rod bearing

: Upper bearing (#1, 5 journal)

Standard dimension

3.75 mm (0.1476 in.)

: Upper bearing (#3 journal)

Standard dimension

1.75 mm (0.0685 in.)

: Upper bearing (#2, 4 journal)

Standard dimension

2.75 mm (0.1083 in.)

: Lower bearing (#1, 5 journal)

Standard dimension

3.75 mm (0.1476 in.)

: Lower bearing (#3 journal)

Standard dimension

1.75 mm (0.0685 in.)

: Lower bearing (#2, 4 journal)

Standard dimension

2.75 mm (0.1083 in.)