2ZR-FE ENGINE MECHANICAL SERVICE DATA
Ignition timing |
Connect terminals 13 (TC) and 4 (CG) of the DLC3 |
0 to 14 degrees BTDC |
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Connect terminals 13 (TC) and 4 (CG) of the DLC3 |
8 to 12 degrees BTDC |
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Engine idle speed |
600 to 700 rpm |
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Compression |
Standard pressure |
1373 kPa (14.0 kgf/cm2, 199 psi) |
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Minimum pressure |
1079 kPa (11.0 kgf/cm2, 157 psi) |
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Difference between each cylinder |
98 kPa (1.0 kgf/cm2, 14.2 psi) |
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V-ribbed belt |
Deflection |
New belt |
7.0 to 8.2 mm (0.276 to 0.322 in.) |
Used belt |
7.6 to 10.0 mm (0.300 to 0.393 in.) |
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Tension |
New belt |
700 to 800N (72 to 81kg, 157.4 to 179.8 lb) |
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Used belt |
550 to 750N (57 to 76kg, 123.7 to 168.6 lb) |
Chain sub-assembly |
Elongation |
Maximum |
115.2 mm (4.535 in.) |
No. 2 Chain sub-assembly |
Elongation |
Maximum |
102.1 mm (4.019 in.) |
Oil pump drive gear |
Minimum gear diameter (with chain sub-assembly) |
Maximum |
48.2 mm (1.898 in.) |
Oil pump drive shaft gear |
Minimum gear diameter (with chain sub-assembly) |
Maximum |
48.2 mm (1.898 in.) |
Camshaft timing gear assembly |
Minimum gear diameter (with chain sub-assembly) |
Maximum |
96.8 mm (3.811 in.) |
Camshaft timing exhaust gear assembly |
Minimum gear diameter (with chain sub-assembly) |
Maximum |
96.8 mm (3.811 in.) |
Crankshaft timing sprocket |
Minimum gear diameter (with chain sub-assembly) |
Maximum |
51.1 mm (2.012 in.) |
Chain tensioner slipper |
Wear |
Maximum |
1.0 mm (0.0394 in.) |
No. 1 chain vibration damper |
Wear |
Maximum |
1.0 mm (0.0394 in.) |
No. 2 chain vibration damper |
Wear |
Maximum |
1.0 mm (0.0394 in.) |
Chain tensioner plate |
Wear |
Maximum |
1.0 mm (0.0394 in.) |
Camshaft |
Circle runout |
Maximum |
0.04 mm (0.00157 in.) |
Cam lobe height |
Standard |
42.816 to 42.916 mm (1.6857 to 1.6896 in.) |
|
Maximum |
42.666 mm (1.6798 in.) |
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Journal diameter |
No. 1 journal |
34.449 to 34.465 mm (1.35626 to 1.35689 in.) |
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Other journals |
22.949 to 22.965 mm (0.90350 to 0.90413 in.) |
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No. 2 camshaft circle runout |
Circle runout |
Maximum |
0.04 mm (0.00157 in.) |
Cam lobe height |
Standard |
44.336 to 44.436 mm (1.7455 to 1.7494 in.) |
|
Maximum |
44.186 mm (1.7396 in.) |
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Journal diameter |
No. 1 journal |
34.449 to 34.465 mm (1.35626 to 1.35689 in.) |
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Other journals |
22.949 to 22.965 mm (0.90350 to 0.90413 in.) |
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Cylinder head set bolt |
Length |
Standard |
146.8 to 148.2 mm (5.7795 to 5.8346 in.) |
Maximum |
149.2 mm (5.874 in.) |
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Diameter |
Standard |
9.77 to 9.96 mm (0.3846 to 0.3921 in.) |
|
Maximum |
9.4 mm (0.3701 in.) |
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Exhaust manifold |
Warpage |
Maximum |
0.7 mm (0.0276 in.) |
Ring pin for Stiffening crankcase assembly |
Protrusion height |
Standard |
3 mm (0.118 in.) |
Cylinder head |
Warpage |
Cylinder block side |
Maximum |
0.05 mm (0.00197 in.) |
Intake manifold side |
Maximum |
0.10 mm (0.00394 in.) |
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Exhaust manifold side |
Maximum |
0.10 mm (0.00394 in.) |
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Camshaft |
Thrust clearance |
Standard |
0.06 to 0.155 mm (0.00236 to 0.00610 in.) |
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Maximum |
0.17 mm (0.00669 in.) |
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Oil clearance |
No. 1 journal |
Standard |
0.030 to 0.063 mm (0.00118 to 0.00248 in.) |
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Maximum |
0.085 mm (0.00335 in.) |
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Other journals |
Standard |
0.035 to 0.072 mm (0.00138 to 0.00283 in.) |
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Maximum |
0.09 mm (0.00354 in.) |
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No. 2 camshaft |
Thrust clearance |
Standard |
0.06 to 0.155 mm (0.00236 to 0.00610 in.) |
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Maximum |
0.17 mm (0.00669 in.) |
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Oil clearance |
No. 1 journal |
Standard |
0.030 to 0.063 mm (0.00118 to 0.00248 in.) |
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Maximum |
0.085 mm (0.00335 in.) |
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Other journals |
Standard |
0.035 to 0.072 mm (0.00138 to 0.00283 in.) |
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Maximum |
0.09 mm (0.00354 in.) |
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Compression spring |
Type A |
Reference free length (New parts) |
53.88 mm (2.12 in.) |
|
Maximum deviation |
1.0 mm (0.0394 in.) |
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Type B |
Reference free length (New parts) |
51.88 mm (2.042 in.) or 51.90 mm (2.043 in.) |
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Maximum deviation |
1.3 mm (0.0512 in.) |
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Intake valve |
Overall length |
Standard |
109.34 mm (4.3047 in.) |
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Maximum |
108.84 mm (4.2850 in.) |
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Valve stem diameter |
Standard |
5.470 to 5.485 mm (0.2154 to 0.2159 in.) |
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Margin thickness |
Standard |
1.0 mm (0.0394 in.) |
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Maximum |
0.5 mm (0.0197 in.) |
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Valve seat width |
Standard |
1.0 to 1.4 mm (0.0394 to 0.0551 in.) |
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Exhaust valve |
Overall length |
Standard |
108.25 mm (4.2618 in.) |
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Maximum |
107.75 mm (4.2421 in.) |
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Valve stem diameter |
Standard |
5.465 to 5.480 mm (0.2152 to 0.2157 in.) |
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Margin thickness |
Standard |
1.01 mm (0.0398 in.) |
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Maximum |
0.5 mm (0.0197 in.) |
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Valve seat width |
Standard |
1.0 to 1.4 mm (0.0394 to 0.0551 in) |
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Intake valve guide bush |
Inside diameter |
Standard |
5.510 to 5.530 mm (0.2169 to 0.2177 in.) |
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Oil clearance |
Standard |
0.025 to 0.060 mm (0.000984 to 0.00236 in.) |
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Maximum |
0.080 mm (0.00315 in.) |
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Bush bore diameter |
STD |
10.333 to 10.344 mm (0.4068 to 0.4072 in.) |
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O/S 0.05 |
10.383 to 10.394 mm (0.4088 to 0.4092 in.) |
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Protrusion height |
Standard |
9.9 to 10.3 mm (0.3898 to 0.4055 in.) |
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Exhaust valve guide bush |
Inside diameter |
Standard |
5.510 to 5.530 mm (0.2169 to 0.2177 in.) |
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Oil clearance |
Standard |
0.030 to 0.065 mm (0.00118 to 0.00256 in.) |
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Maximum |
0.085 mm (0.00335 in.) |
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Bush bore diameter |
STD |
10.333 to 10.344 mm (0.4068 to 0.4072 in.) |
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O/S 0.05 |
10.383 to 10.394 mm (0.4088 to 0.4092 in.) |
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Protrusion height |
Standard |
11.15 to 11.55 mm (0.4390 to 0.4547 in.) |
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Ring pin for cylinder head cover sub-assembly |
Protrusion height |
Standard |
6.5 to 7.5 mm (0.256 to 0.295 in.) |
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Spark plug tube |
Protrusion height |
Standard |
122 mm (4.80 in.) |
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Connecting rod thrust clearance |
Standard |
0.160 to 0.342 mm (0.00630 to 0.0135 in.) |
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Maximum |
0.342 mm (0.0135 in.) |
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Connecting rod oil clearance |
Crankshaft side |
Standard |
0.014 to 0.038 mm (0.000551 to 0.00150 in.) |
Maximum |
0.070 mm (0.00276 in.) |
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Piston side |
Standard |
0.005 to 0.011 mm (0.000197 to 0.000433 in.) |
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Maximum |
0.014 mm (0.000551 in.) |
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Connecting rod bearing dimension (A-B) |
0.7 mm (0.0276 in.) or less |
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Connecting rod small end bore diameter |
Standard |
20.012 to 20.021 mm (0.7879 to 0.7882 in.) |
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Connecting rod small end bore diameter |
Mark A |
20.012 to 20.015 mm (0.78787 to 0.78799 in.) |
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Mark B |
20.016 to 20.018 mm (0.78803 to 0.78811 in.) |
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Mark C |
20.019 to 20.021 mm (0.78815 to 0.78823 in.) |
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Connecting rod large end bore diameter |
Mark 1 |
47.000 to 47.008 mm (1.85039 to 1.85070 in.) |
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Mark 2 |
47.009 to 47.016 mm (1.85074 to 1.85102 in.) |
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Mark 3 |
47.017 to 47.024 mm (1.85106 to 1.85133 in.) |
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Connecting rod bearing thickness |
Mark 1 |
1.489 to 1.493 mm (0.058621 to 0.058779 in.) |
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Mark 2 |
1.494 to 1.497 mm (0.058819 to 0.058937 in.) |
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Mark 3 |
1.498 to 1.501 mm (0.058976 to 0.059094 in.) |
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Crankshaft pin diameter |
Standard |
43.992 to 44.000 mm (1.7320 to 1.7323 in.) |
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Cylinder block sub-assembly warpage |
Maximum |
0.05 mm (0.00197 in.) |
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Cylinder bore diameter |
Standard |
80.500 to 80.513 mm (3.1693 to 3.1698 in.) |
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Maximum |
80.633 mm (3.1745 in.) |
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Piston diameter |
Standard |
80.471 to 80.491 mm (3.16814 to 3.16893 in.) |
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Piston oil clearance |
Standard |
0.009 to 0.042 mm (0.000354 to 0.00165 in.) |
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Maximum |
0.08 mm (0.00315 in.) |
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Piston ring groove clearance |
No. 1 Ring |
0.02 to 0.07 mm (0.000787 to 0.00276 in.) |
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No. 2 Ring |
0.02 to 0.06 mm (0.000787 to 0.00236 in.) |
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Oil Ring (2-piece Type) |
0.02 to 0.065 mm (0.000787 to 0.00256 in.) |
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Oil Ring (3-piece Type) |
0.07 to 0.13 mm (0.00276 to 0.00512 in.) |
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Piston ring end gap |
No. 1 compression ring |
Standard |
0.20 to 0.30 mm (0.00787 to 0.0118 in.) |
Maximum |
0.50 mm (0.0197 in.) |
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No. 2 compression ring |
Standard |
0.30 to 0.50 mm (0.0118 to 0.0197 in.) |
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Maximum |
0.70 mm (0.0276 in.) |
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Oil ring (2-piece Type) |
Standard |
0.10 to 0.40 mm (0.00394 to 0.0157 in.) |
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Maximum |
0.70 mm (0.0276 in.) |
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Oil ring (3-piece Type) |
Standard |
0.10 to 0.35 mm (0.00394 to 0.0138 in.) |
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Maximum |
0.70 mm (0.0276 in.) |
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Piston pin diameter |
Mark A |
20.004 to 20.007 mm (0.78756 to 0.78768 in.) |
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Mark B |
20.008 to 20.010 mm (0.78771 to 0.78779 in.) |
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Mark C |
20.011 to 20.013 mm (0.78783 to 0.78791 in.) |
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Piston pin bore diameter |
Mark A |
20.006 to 20.009 mm (0.78764 to 0.78775 in.) |
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Mark B |
20.010 to 20.012 mm (0.78779 to 0.78787 in.) |
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Mark C |
20.013 to 20.015 mm (0.78791 to 0.78799 in.) |
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Piston pin oil clearance |
Standard |
-0.001 to 0.005 mm (-0.0000394 to 0.000197 in.) |
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Maximum |
0.008 mm (0.000315 in.) |
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Connecting rod misalignment |
Maximum |
0.05 mm (0.00197 in.) per 100 mm (3.94 in.) |
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Connecting rod twist |
Maximum |
0.15 mm (0.00591 in.) per 100 mm (3.94 in.) |
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Crankshaft thrust clearance |
Standard |
0.04 to 0.14 mm (0.00157 to 0.00551 in.) |
|
Maximum |
0.18 mm (0.00709 in.) |
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Thrust washer thickness |
2.43 to 2.48 mm (0.0957 to 0.0976 in.) |
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Main journal diameter (Reference) |
Mark 0 |
47.999 to 48.000 mm (1.88972 to 1.88976 in.) |
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Mark 1 |
47.999 to 48.000 mm (1.88972 to 1.88976 in.) |
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Mark 2 |
47.995 to 47.996 mm (1.88956 to 1.88960 in.) |
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Mark 3 |
47.993 to 47.994 mm (1.88948 to 1.88952 in.) |
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Mark 4 |
47.991 to 47.992 mm (1.88941 to 1.88945 in.) |
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Mark 5 |
47.988 to 47.990 mm (1.88929 to 1.88937 in.) |
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Crank pin diameter |
Standard |
43.992 to 44.000 mm (1.7320 to 1.7323 in.) |
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Taper and distortion |
Maximum |
0.004 mm (0.000157 in.) |
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Crankshaft oil clearance |
Standard |
0.016 to 0.039 mm (0.000630 to 0.00154 in.) |
|
Maximum |
0.050 mm (0.00197 in.) |
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Cylinder block main journal bore diameter (Reference) |
Mark 0 |
52.000 to 52.002 mm (2.04724 to 2.04732 in.) |
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Mark 1 |
52.003 to 52.004 mm (2.04736 to 2.04740 in.) |
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Mark 2 |
52.005 to 52.006 mm (2.04744 to 2.04748 in.) |
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Mark 3 |
52.007 to 52.009 mm (2.04752 to 2.04759 in.) |
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Mark 4 |
52.010 to 52.011 mm (2.04763 to 2.04767 in.) |
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Mark 5 |
52.012 to 52.013 mm (2.04771 to 2.04775 in.) |
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Mark 6 |
52.014 to 52.016 mm (2.04779 to 2.04787 in.) |
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Crankshaft journal diameter (Reference) |
Mark 0 |
47.999 to 48.000 mm (1.88972 to 1.88976 in.) |
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Mark 1 |
47.997 to 47.998 mm (1.88964 to 1.88968 in.) |
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Mark 2 |
47.995 to 47.996 mm (1.88956 to 1.88961 in.) |
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Mark 3 |
47.995 to 47.996 mm (1.88956 to 1.88961 in.) |
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Mark 4 |
47.991 to 47.992 mm (1.88941 to 1.88945 in.) |
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Mark 5 |
47.988 to 47.990 mm (1.88929 to 1.88937 in.) |
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Crankshaft main bearing center wall thickness (Reference) |
Mark 1 |
1.994 to 1.997 mm (0.07850 to 0.07862 in.) |
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Mark 2 |
1.998 to 2.000 mm (0.07866 to 0.07874 in.) |
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Mark 3 |
2.001 to 2.003 mm (0.07878 to 0.07886 in.) |
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Mark 4 |
2.004 to 2.006 mm (0.07890 to 0.07898 in.) |
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Crankshaft bearing cap set bolt length |
Standard |
84.3 to 85.7 mm (3.3189 to 3.3740 in.) |
|
Maximum |
86.7 mm (3.4134 in.) |
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Crankshaft bearing cap set bolt diameter |
Standard |
9.77 to 9.96 mm (0.3846 to 0.3921 in.) |
|
Maximum |
9.1 mm (0.3583 in.) |
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Connecting rod small end bush |
Standard |
-0.002 to 0.004 mm (-0.0000787 to 0.000157) |
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No. 1 ventilation case seal diameter |
Standard |
2.0 to 3.0 mm (0.0787 to 0.118 in.) |
|
Crankshaft bearing |
Dimension A |
0.5 to 1.0 mm (0.0197 to 0.0394 in.) |
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Dimension A-B |
0.5 mm (0.0197 in.) or less |
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Straight pin protrusion height |
Pin A |
18.5 to 19.5 mm (0.728 to 0.768 in.) |
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Pin B |
5.0 to 7.0 mm (0.197 to 0.276 in.) |
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Pin C |
11 to 13 mm (0.433 to 0.512 in.) |
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Pin D |
8.0 to 10.0 mm (0.315 to 0.394 in.) |
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Pin E |
5.0 to 6.0 mm (0.197 to 0.236 in.) |
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