2GR-FKS ENGINE MECHANICAL SERVICE DATA

ENGINE
Ignition timing Terminals 13 (TC) and 4 (CG) of the DLC3 connected 8 to 12° BTDC at idle (Transaxle should be in neutral or park)
Terminals 13 (TC) and 4 (CG) of the DLC3 disconnected 12 to 24° BTDC at idle (Transaxle should be in neutral or park)
Engine idle speed 600 to 700 rpm (Transaxle should be in neutral or park)
Compression Standard compression pressure

1400 kPa (14.3 kgf/cm2, 203 psi)
Minimum compression pressure

1050 kPa (10.7 kgf/cm2, 152 psi)
Pressure difference between each cylinder

200 kPa (2.0 kgf/cm2, 29 psi) or less
FRONT CRANKSHAFT OIL SEAL
Timing chain case oil seal Depth Standard 0 to 1.0 mm (0 to 0.0394 in.)
REAR CRANKSHAFT OIL SEAL
Rear engine oil seal Depth Standard -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
ENGINE UNIT
Camshaft Runout Maximum 0.04 mm (0.00157 in.)
Cam lobe height Intake Standard 44.335 to 44.435 mm (1.74547 to 1.74941 in.)
Minimum 44.235 mm (1.74154 in.)
Exhaust Standard 43.866 to 43.966 mm (1.72701 to 1.73094 in.)
Minimum 43.766 mm (1.72307 in.)
Exhaust (for Fuel Pump) Standard 40.554 to 40.654 mm (1.59661 to 1.60055 in.)
Minimum 40.454 mm (1.59268 in.)
Journal diameter No. 1 journal Standard 35.946 to 35.960 mm (1.41519 to 1.41575 in.)
No. 2, No. 3, No. 4 journals Standard 25.959 to 25.975 mm (1.02201 to 1.02264 in.)
No. 5 journal Standard 25.969 to 25.985 mm (1.02240 to 1.02303 in.)
Thrust clearance Standard 0.08 to 0.13 mm (0.00315 to 0.00512 in.)
Maximum 0.18 mm (0.00709 in.)
for Bank 1: Oil clearance No. 1 journal Standard 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
Maximum 0.10 mm (0.00394 in.)
No. 2, No. 3, No. 4 journals Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.10 mm (0.00394 in.)
No. 5 journal Standard 0.015 to 0.052 mm (0.000591 to 0.00205 in.)
Maximum 0.10 mm (0.00394 in.)
for Bank 2: Oil clearance No. 1 journal Standard 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
Maximum 0.10 mm (0.00394 in.)
Other journals Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum 0.10 mm (0.00394 in.)
Cylinder head set bolt Diameter Standard 10.85 to 11.00 mm (0.427 to 0.433 in.)
Minimum 10.70 mm (0.421 in.)
Chain sub-assembly Elongation Maximum 137.8 mm (5.43 in.)
No. 2 chain sub-assembly Elongation Maximum 137.8 mm (5.43 in.)
Crankshaft timing sprocket Diameter (with Chain sub-assembly) Maximum 62.2 mm (2.45 in.)
Idle sprocket assembly Diameter (with Chain sub-assembly) Maximum 65.2 mm (2.57 in.)
Idle gear shaft No. 1 idle gear shaft diameter Standard 22.987 to 23.000 mm (0.905 to 0.906 in.)
Idle sprocket assembly 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 Wear depth Maximum 1.0 mm (0.0394 in.)
No. 3 chain tensioner assembly Wear depth Maximum 1.0 mm (0.0394 in.)
Chain tensioner slipper Wear depth Maximum 1.0 mm (0.0394 in.)
No. 1 chain vibration damper Wear depth Maximum 1.0 mm (0.0394 in.)
No. 2 chain vibration damper Wear depth Maximum 1.0 mm (0.0394 in.)
Intake manifold Warpage Maximum 0.1 mm (0.00394 in.)
Exhaust manifold Warpage Maximum 0.7 mm (0.0276 in.)
Rear engine oil seal Protrusion height Standard -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Straight pin Protrusion height Standard 7.7 to 8.3 mm (0.303 to 0.327 in.)
Camshaft bearing cap setting ring pin Protrusion height Standard 2.7 to 3.3 mm (0.106 to 0.130 in.)
CYLINDER HEAD
Cylinder head Warpage Standard Bottom side 0.05 mm (0.00197 in.)
Standard Intake manifold side 0.08 mm (0.00315 in.)
Standard Exhaust manifold side 0.08 mm (0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Valve guide bush bore diameter Use STD 10.285 to 10.306 mm (0.405 to 0.406 in.)
Use O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 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.)
Minimum 0.5 mm (0.0197 in.)
Overall length Standard 105.85 mm (4.17 in.)
Minimum 105.35 mm (4.15 in.)
Valve seat width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 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.)
Minimum 0.5 mm (0.0197 in.)
Overall length Standard 110.40 mm (4.35 in.)
Minimum 109.90 mm (4.33 in.)
Valve seat width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 in.)
Inner compression spring Free length Standard 54.53 mm (2.15 in.)
Minimum 52.43 mm (2.06 in.)
Deviation (Reference) Maximum 1.4 mm (0.0551 in.)
Intake 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 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.12 mm (0.00472 in.)
Bush bore diameter STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)
Protrusion height Standard 9.30 to 9.70 mm (0.366 to 0.382 in.)
Exhaust valve guide bush Bush inside diameter Standard 5.510 to 5.530 mm (0.217 to 0.218 in.)
Oil clearance Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.12 mm (0.00472 in.)
Bush bore diameter STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)
Protrusion height Standard 9.30 to 9.70 mm (0.366 to 0.382 in.)
Ring pin Protrusion height Standard 2.5 to 3.5 mm (0.0984 to 0.138 in.)
Straight pin Protrusion height Standard 17.5 to 19.5 mm (0.689 to 0.768 in.)
Spark plug tube Protrusion height Standard 73 mm (2.87 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 0.045 to 0.067 mm (0.00177 to 0.00264 in.)
Maximum 0.070 mm (0.00276 in.)
Standard connecting rod diameter Mark 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
Mark 2 56.007 to 56.012 mm (2.20500 to 2.20519 in.)
Mark 3 56.013 to 56.018 mm (2.20523 to 2.20543 in.)
Mark 4 56.019 to 56.024 mm (2.20547 to 2.20566 in.)
Standard connecting rod bearing center wall thickness Mark 1 1.482 to 1.485 mm (0.05835 to 0.05846 in.)
Mark 2 1.486 to 1.488 mm (0.05850 to 0.05858 in.)
Mark 3 1.489 to 1.491 mm (0.05862 to 0.05870 in.)
Mark 4 1.492 to 1.494 mm (0.05874 to 0.05882 in.)
Cylinder block warpage Maximum 0.07 mm (0.00276 in.)
Cylinder bore diameter Reference diameter (New parts) 94.000 to 94.012 mm (3.70078 to 3.70125 in.)
Maximum 94.130 mm (3.70590 in.)
Piston diameter Reference diameter (New parts) 93.962 to 93.992 mm (3.69928 to 3.70047 in.)
Minimum 93.830 mm (3.69409 in.)
Piston oil clearance Reference oil clearance (New parts) 0.008 to 0.050 mm (0.000315 to 0.00197 in.)
Maximum 0.075 mm (0.00295 in.)
Standard piston ring groove clearance No. 1 compression ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
No. 2 compression ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
Oil ring 0.070 to 0.150 mm (0.00276 to 0.00591 in.)
Standard piston pin hole inside diameter Mark A 21.998 to 22.001 mm (0.86606 to 0.86618 in.)
Mark B 22.002 to 22.004 mm (0.86622 to 0.86630 in.)
Mark C 22.005 to 22.007 mm (0.86634 to 0.86642 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 Standard -0.002 to 0.004 mm (-0.0000787 to 0.000157 in.)
Maximum 0.015 mm (0.000591 in.)
Standard 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.)
Piston ring end gap No. 1 compression ring Standard 0.22 to 0.27 mm (0.00866 to 0.0106 in.)
Maximum 0.50 mm (0.0197 in.)
No. 2 compression ring Standard 0.70 to 0.75 mm (0.0276 to 0.0295 in.)
Maximum 0.85 mm (0.0335 in.)
Oil ring Standard 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum 0.45 mm (0.0177 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.)
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 runout Maximum 0.06 mm (0.00236 in.)
Crank main journal Main journal diameter Standard 60.988 to 61.000 mm (2.40110 to 2.40157 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crank pin Crankshaft pin diameter Standard 52.992 to 53.000 mm (2.08630 to 2.08661 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crankshaft oil clearance No. 1 journal and No. 4 journal Standard 0.019 to 0.029 mm (0.000748 to 0.00114 in.)
Maximum 0.050 mm (0.00197 in.)
No. 2 journal and No. 3 journal Standard 0.025 to 0.035 mm (0.000984 to 0.00138 in.)
Maximum 0.060 mm (0.00236 in.)
Standard crankshaft Main Journal Diameter Mark 00 60.999 to 61.000 mm (2.40153 to 2.40157 in.)
Mark 01 60.998 to 60.999 mm (2.40149 to 2.40153 in.)
Mark 02 60.997 to 60.998 mm (2.40145 to 2.40149 in.)
Mark 03 60.996 to 60.997 mm (2.40141 to 2.40145 in.)
Mark 04 60.995 to 60.996 mm (2.40137 to 2.40141 in.)
Mark 05 60.994 to 60.995 mm (2.40133 to 2.40137 in.)
Mark 06 60.993 to 60.994 mm (2.40129 to 2.40133 in.)
Mark 07 60.992 to 60.993 mm (2.40126 to 2.40129 in.)
Mark 08 60.991 to 60.992 mm (2.40122 to 2.40126 in.)
Mark 09 60.990 to 60.991 mm (2.40118 to 2.40122 in.)
Mark 10 60.989 to 60.990 mm (2.40114 to 2.40118 in.)
Mark 11 60.988 to 60.989 mm (2.40110 to 2.40114 in.)
Standard upper crankshaft bearing center wall thickness (No. 1 and No. 4 journal) Mark 1 2.497 to 2.500 mm (0.09831 to 0.09843 in.)
Mark 2 2.501 to 2.503 mm (0.09846 to 0.09854 in.)
Mark 3 2.504 to 2.506 mm (0.09858 to 0.09866 in.)
Mark 4 2.507 to 2.509 mm (0.09870 to 0.09878 in.)
Mark 5 2.510 to 2.512 mm (0.09882 to 0.09890 in.)
Standard lower crankshaft 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 crankshaft bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.476 to 2.479 mm (0.09748 to 0.09760 in.)
Mark 2 2.480 to 2.482 mm (0.09764 to 0.09772 in.)
Mark 3 2.483 to 2.485 mm (0.09776 to 0.09783 in.)
Mark 4 2.486 to 2.488 mm (0.09787 to 0.09795 in.)
Mark 5 2.489 to 2.491 mm (0.09799 to 0.09807 in.)
Standard lower crankshaft bearing center wall thickness (No. 2 and No. 3 journal) Mark 1 2.493 to 2.496 mm (0.09815 to 0.09827 in.)
Mark 2 2.497 to 2.499 mm (0.09831 to 0.09839 in.)
Mark 3 2.500 to 2.502 mm (0.09843 to 0.09850 in.)
Mark 4 2.503 to 2.505 mm (0.09854 to 0.09862 in.)
Mark 5 2.506 to 2.508 mm (0.09866 to 0.09874 in.)
Crankshaft bearing cap set bolt diameter Standard 10.8 to 11.0 mm (0.425 to 0.433 in.)
Minimum 10.7 mm (0.421 in.)
Straight pin Standard protrusion height Pin (A) 23 mm (0.906 in.)
Pin (B) 6 mm (0.236 in.)
Pin (C) 11 mm (0.433 in.)
Pin (D) 9 mm (0.354 in.)