4GR-FSE ENGINE MECHANICAL SERVICE DATA

ENGINE
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 7 to 17° BTDC at idle (Transmission in neutral)
Idle speed 650 to 750 rpm (Transmission in neutral)
Compression Compression pressure

1400 kPa (14.3 kgf/cm2, 199 psi) or higher
Minimum pressure

980 kPa (10.0 kgf/cm2, 142 psi)
Difference between each cylinder

100 kPa (1.0 kgf/cm2, 15 psi) or less
ENGINE UNIT
Camshaft Circuit runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Intake Standard 43.940 to 44.040 mm (1.7299 to 1.7339 in.)
Maximum 43.790 mm (1.7240 in.)
Exhaust Standard 44.090 to 44.190 mm (1.7358 to 1.7398 in.)
Maximum 43.940 mm (1.7299 in.)
Journal diameter No. 1 journal Standard 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals Standard 25.959 to 25.975 mm (1.0220 to 1.0226 in.)

for Bank 1:

Oil clearance

 No. 1 journal Standard 0.032 to 0.071 mm (0.00122 to 0.00280 in.)
Maximum 0.10 mm (0.00394 in.)
No. 2, 3, 4 journals Standard 0.025 to 0.062 mm (0.000984 to 0.00240 in.)
No. 5 journal Standard 0.015 to 0.052 mm (0.000591 to 0.00205 in.)
Other journals Maximum 0.09 mm (0.00354 in.)

for Bank 2:

Oil clearance

 No. 1 journal Standard 0.032 to 0.071 mm (0.00122 to 0.00280 in.)
Maximum 0.10 mm (0.00394 in.)
Other journals Standard 0.025 to 0.062 mm (0.000984 to 0.00240 in.)
Maximum 0.09 mm (0.00354 in.)
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.)
Diameter Standard 10.80 to 11.00 mm (0.425 to 0.433 in.)
Minimum 10.70 mm (0.421 in.)
Chain Elongation Maximum 136.9 mm (5.39 in.)
No. 2 chain Elongation Maximum 137.6 mm (5.42 in.)
Crankshaft timing gear or sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.42 in.)
Idle sprocket Diameter (w/ Chain) Minimum 61.4 mm (2.42 in.)
Idle gear shaft Idle gear shaft diameter Standard 22.987 to 23.000 mm (0.905 to 0.906 in.)
Idle gear inside diameter Standard 23.020 to 23.030 mm (0.906 to 0.907 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 (0.0393 in.)
No. 1 chain vibration damper Worn depth Maximum 1.0 mm (0.0393 in.)
No. 2 chain vibration damper Worn depth Maximum 1.0 mm (0.0393 in.)
Exhaust manifold sub-assembly Warpage Maximum 0.70 mm (0.0276 in.)
Intake Manifold Warpage Maximum 0.10 mm (0.00394 in.)
CYLINDER HEAD
Cylinder head sub-assembly Warpage Standard Cylinder Block Side 0 to 0.05 mm (0 to 0.00197 in.)
Standard Intake Side 0 to 0.08 mm (0 to 0.00315 in.)
Standard Exhaust Side 0 to 0.08 mm (0 to 0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Intake valve Valve stem diameter Standard 5.470 to 5.485 mm (0.215 to 0.216 in.)
Margin thickness Standard 1.0 mm (0.0394 in.)
Maximum 0.5 mm (0.0197 in.)
Overall length Standard 106.15 mm (4.18 in.)
Maximum 105.65 mm (4.16 in.)
Exhaust valve Valve stem diameter Standard 5.465 to 5.480 mm (0.215 to 0.216 in.)
Margin thickness Standard 0.81 mm (0.0319 in.)
Maximum 0.31 mm (0.0122 in.)
Overall length Standard 111.70 mm (4.40 in.)
Maximum 111.20 mm (4.38 in.)
Inner compression spring Free length 48.05 mm (1.89 in.)
Deviation Maximum 1.0 mm (0.0394 in.)
Angle (reference) Maximum 2°
Intake valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Standard 0.030 to 0.060 mm (0.00118 to 0.00236 in.)
Maximum 0.08 mm (0.00315 in.)
Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height Standard 10.2 to 10.6 mm (0.402 to 0.417 in.)
Exhaust valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Standard 0.025 to 0.065 mm (.0.000984 to 0.00256 in.)
Maximum 0.01 mm (0.000394 in.)
Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Protrusion height Standard 9.30 to 9.70 mm (0.366 to 0.382 in.)
Camshaft 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 Standard 2.5 to 3.8 mm (0.0984 to 0.150 in.)
Straight pin for cylinder head sub-assembly Protrusion height Standard 17.5 to 19.5 mm (0.689 to 0.768 in.)
CYLINDER BLOCK
Connecting rod thrust clearance Standard 0.25 to 0.40 mm (0.00984 to 0.0157 in.)
Maximum 0.50 mm (0.0197 in.)
Connecting rod oil clearance Standard 0.026 to 0.046 mm (0.00102 to 0.00181 in.)
Maximum 0.070 mm (0.00276 in.)
Connecting rod diameter Mark 1 51.000 to 51.006 mm (2.00787 to 2.00811 in.)
Mark 2 51.007 to 51.012 mm (2.00815 to 2.00834 in.)
Mark 3 51.013 to 51.018 mm (2.00838 to 2.00858 in.)
Mark 4 51.019 to 51.024 mm (2.00862 to 2.00881 in.)
Connecting rod beating 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 0.05890 in.)
Crankshaft pin diameter Standard 47.992 to 48.000 mm (1.8894 to 1.8898 in.)
Cylinder block warpage Standard 0 to 0.05 mm (0 to 0.00197 in.)
Maximum 0.07 mm (0.00276 in.)
Cylinder bore diameter Standard 83.000 to 83.012 mm (3.2677 to 3.2682 in.)
Maximum 83.200 mm (3.2756 in.)
Piston diameter Distance 14.3 mm (0.563 in.)
Standard 82.976 to 82.986 mm (3.2668 to 3.2672 in.)
Maximum 82.846 mm (3.2616 in.)
Piston oil clearance Standard 0.006 to 0.052 mm (0.000236 to 0.002047 in.)
Maximum 0.072 mm (0.002835 in.)
Piston ring groove clearance No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 0.030 to 0.070 mm (0.00118 to 0.00276 in.)
Oil 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
Piston pin hole inside diameter Mark A 21.998 to 22.001 mm (0.8661 to 0.8662 in.)
Mark B 22.002 to 22.004 mm (0.8662 to 0.8663 in.)
Mark C 22.005 to 22.007 mm (0.8663 to 0.8664 in.)
Piston pin diameter Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 in.)
Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 in.)
Piston pin oil clearance Standard -0.002 to 0.004 mm (-0.0000787 to 0.000158 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.)
Connecting rod bushing oil clearance Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.030 mm (0.00118 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.)
Piston ring end gap No. 1 Standard 0.20 to 0.25 mm (0.00787 to 0.00984 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 Standard 0.35 to 0.40 mm (0.0138 to 0.0157 in.)
Maximum 0.80 mm (0.0315 in.)
Oil (Side rail) Standard 0.10 to 0.20 mm (0.00394 to 0.00787 in.)
Maximum 0.65 mm (0.0256 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.)
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 circle runout Maximum 0.06 mm (0.00236 in.)
Main journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
Crank main journal Journal diameter Standard 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crank pin Crank pin diameter Standard 47.992 to 48.000 mm (1.889 to 1.890 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crankshaft oil clearance No. 1, No. 4 journal Standard 0.026 to 0.047 mm (0.00102 to 0.00185 in.)
Minimum 0.050 mm (0.00197 in.)
No. 2, No. 3 journal Standard 0.032 to 0.053 mm (0.00126 to 0.00209 in.)
Minimum 0.060 mm (0.00236 in.)
Standard upper bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
Mark 2 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
Mark 3 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
Mark 4 2.510 to 2.512 mm (0.09881 to 0.09890 in.)
Mark 5 2.513 to 2.515 mm (0.09894 to 0.09902 in.)
Standard lower bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 2 2.482 to 2.484 mm (0.09772 to 0.09780 in.)
Mark 3 2.485 to 2.487 mm (0.09783 to 0.09791 in.)
Mark 4 2.488 to 2.490 mm (0.09795 to 0.09803 in.)
Mark 5 2.491 to 2.493 mm (0.09807 to 0.09815 in.)
Standard upper bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 2 2.482 to 2.484 mm (0.09772 to 0.09780 in.)
Mark 3 2.485 to 2.487 mm (0.09783 to 0.09791 in.)
Mark 4 2.488 to 2.490 mm (0.09795 to 0.09803 in.)
Mark 5 2.491 to 2.493 mm (0.09807 to 0.09815 in.)
Standard lower bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
Mark 2 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
Mark 3 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
Mark 4 2.510 to 2.512 mm (0.09881 to 0.09890 in.)
Mark 5 2.513 to 2.515 mm (0.09894 to 0.09902 in.)
Crankshaft bearing cap set bolt diameter Standard 10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Minimum 10.7 mm (0.4213 in.)
Measuring point 47 mm (1.85 in.)
Straight pin for cylinder block sub-assembly Protrusion height Pin A 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B 5.5 to 6.5 mm (0.217 to 0.256 in.)
Pin C 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin D 8.5 to 9.5 mm (0.335 to 0.374 in.)