2GR-FXE ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminals TC and CG of DLC3 connected 8 to 12° BTDC at idle (Transmission in park)
Terminals TC and CG of DLC3 disconnected 8 to 18° BTDC at idle (Transmission in park)
Idle speed 950 to 1050 rpm (Transmission in park)
Compression Compression pressure

1000 kPa (10.2 kgf/cm2, 145 psi) or higher
Minimum pressure

700 kPa (7.1 kgf/cm2, 102 psi)
Difference between each cylinder

200 kPa (2.0 kgf/cm2, 29 psi) or less
ENGINE UNIT
Camshaft Circuit runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Intake Standard 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
Maximum 44.168 mm (1.7389 in.)
Exhaust Standard 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
Maximum 44.191 mm (1.7398 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 (0.0394 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.)
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 105.85 mm (4.17 in.)
Maximum 105.35 mm (4.15 in.)
Exhaust valve Valve stem diameter Standard 5.465 to 5.480 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 110.40 mm (4.35 in.)
Maximum 109.90 mm (4.33 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 9.1 to 9.9 mm (0.358 to 0.390 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 9.1 to 9.9 mm (0.358 to 0.390 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 0.15 to 0.40 mm (0.00591 to 0.0157 in.)
Maximum 0.50 mm (0.0197 in.)
Connecting rod oil clearance Standard 0.032 to 0.052mm (0.00126 to 0.00205 in.)
Maximum 0.070 mm (0.00276 in.)
Connecting rod diameter Mark 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
Mark 2 56.006 to 56.012 mm (2.20496 to 2.20519 in.)
Mark 3 56.012 to 56.018 mm (2.20519 to 2.20543 in.)
Mark 4 56.018 to 56.024 mm (2.20543 to 2.20566 in.)
Connecting rod beating center wall thickness Mark 1 1.481 to 1.484 mm (0.05831 to 0.05843 in.)
Mark 2 1.484 to 1.487 mm (0.05843 to 0.05854 in.)
Mark 3 1.487 to 1.490 mm (0.05854 to 0.05866 in.)
Mark 4 1.490 to 1.493 mm (0.05866 to 0.05878 in.)
Crankshaft pin diameter Standard 52.992 to 53.000 mm (2.0863 to 2.0866 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 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum 94.200 mm (3.7087 in.)
Piston diameter Distance 8.7 mm (0.3425 in.)
Standard 93.956 to 93.986 mm (3.6990 to 3.7002 in.)
Maximum 93.826 mm (3.6939 in.)
Piston oil clearance Standard 0.014 to 0.056 mm (0.00055 to 0.00220 in.)
Maximum 0.090 mm (0.00354 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 0.020 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 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
Mark C 22.004 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 22.000 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 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 22.008 to 22.011 mm (0.86645 to 0.86657 in.)
Mark C 22.011 to 22.014 mm (0.86657 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 0.23 to 0.33 mm (0.00906 to 0.0130 in.)
Maximum 0.40 mm (0.0157 in.)
No. 2 Standard 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Maximum 0.50 mm (0.0197 in.)
Oil (Side rail) Standard 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
Maximum 0.45 mm (0.0177 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 8.5 to 8.6 mm (0.335 to 0.339 in.)
Minimum 8.3 mm (0.327 in.)
Crankshaft circle runout Maximum 0.06 mm (0.00236 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 52.992 to 53.000 mm (2.0863 to 2.0866 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 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
Mark 3 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
Mark 4 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
Mark 5 2.512 to 2.515 mm (0.09890 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 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
Mark 3 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
Mark 4 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
Mark 5 2.490 to 2.493 mm (0.09803 to 0.09815 in.)
Standard upper bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.475 to 2.478 mm (0.09744 to 0.09756 in.)
Mark 2 2.478 to 2.481 mm (0.09756 to 0.09768 in.)
Mark 3 2.481 to 2.484 mm (0.09768 to 0.09780 in.)
Mark 4 2.484 to 2.487 mm (0.09780 to 0.09791 in.)
Mark 5 2.487 to 2.490 mm (0.09791 to 0.09803 in.)
Standard lower bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.497 to 2.500 mm (0.09831 to 0.09843 in.)
Mark 2 2.500 to 2.503 mm (0.09843 to 0.09854 in.)
Mark 3 2.503 to 2.506 mm (0.09854 to 0.09866 in.)
Mark 4 2.506 to 2.509 mm (0.09866 to 0.09878 in.)
Mark 5 2.509 to 2.512 mm (0.09878 to 0.09890 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.)