Engine Mechanical (Service Specifications): Other

SERVICE DATA [04/2013 - ]

Ignition timing	Connect terminals 13 (TC) and 4 (CG) of the DLC3	Standard	8 to 12 degrees BTDC at idle
Ignition timing	Disconnect terminals 13 (TC) and 4 (CG) of the DLC3	Standard	7 to 17 degrees BTDC at idle
Idle speed		Standard	600 to 700 rpm
Compression pressure		Standard pressure	1400 kPa (14.3 kgf/cm 2 , 203 psi)
		Minimum pressure	980 kPa (10.0 kgf/cm 2 , 142 psi)
		Difference between each cylinder	100 kPa (1.0 kgf/cm 2 , 15 psi)

ENGINE

Exhaust manifold sub-assembly

Maximum warpage

0.70 mm (0.02756 in.)

ENGINE ASSEMBLY

Camshaft	Circuit runout	Maximum	0.08 mm (0.00315 in.)
	Cam lobe height	Intake	Standard	43.940 to 44.040 mm (1.7299 to 1.7339 in.)
		Intake	Maximum	43.790 mm (1.7240 in.)
		Exhaust	Standard	44.090 to 44.190 mm (1.7358 to 1.7398 in.)
		Exhaust	Maximum	43.940 mm (1.7299 in.)
		Exhaust (for fuel pump)	Standard	56.450 to 56.550 mm (2.2224 to 2.2264 in.)
		Exhaust (for fuel pump)	Maximum	56.300 mm (2.2165 in.)
	Journal diameter	No. 1 journal	Standard	35.946 to 35.960 mm (1.4152 to 1.4157 in.)
	Journal diameter	Other journals	Standard	25.959 to 25.975 mm (1.0220 to 1.0226 in.)
	For Bank 1: Oil clearance	Exhaust side No. 1 journal	Standard	0.031 to 0.078 mm (0.00122 to 0.00307 in.)
		Exhaust side No. 1 journal	Maximum	0.10 mm (0.00394 in.)
		Other journals	Standard	0.025 to 0.062 mm (0.00098 to 0.00244 in.)
		Other journals	Maximum	0.09 mm (0.00354 in.)
	For Bank 2: Oil clearance	Exhaust side No. 1 journal	Standard	0.031 to 0.078 mm (0.00122 to 0.00307 in.)
		Exhaust side No. 1 journal	Maximum	0.10 mm (0.00394 in.)
		Other journals	Standard	0.025 to 0.062 mm (0.00098 to 0.00244 in.)
		Other journals	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.)
	Length	Maximum	143.7 mm (5.66 in.)
	Diameter	Standard	10.80 to 11.00 mm (0.425 to 0.433 in.)
	Diameter	Minimum	10.70 mm (0.421 in.)
Chain sub-assembly	Elongation	Maximum	136.9 mm (5.39 in.)
No. 2 chain sub-assembly	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 assembly	Diameter (w/ Chain)	Minimum	61.4 mm (2.42 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 (0.00079 to 0.00169 in.)
	Oil clearance	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.)

ENGINE UNIT

Cylinder head sub-assembly	Warpage	Standard	Cylinder Block Sub-assembly 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.)
	Margin thickness	Minimum	0.5 mm (0.0197 in.)
	Overall length	Standard	106.15 mm (4.18 in.)
	Overall length	Minimum	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.)
	Margin thickness	Minimum	0.31 mm (0.0122 in.)
	Overall length	Standard	111.70 mm (4.40 in.)
	Overall length	Minimum	111.20 mm (4.38 in.)
Inner compression spring	Free length	Standard	57.46 mm (2.26 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.)
	Oil clearance	Maximum	0.08 mm (0.00315 in.)
	Bush bore diameter	Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
	Bush bore diameter	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 (0.00098 to 0.00256 in.)
	Oil clearance	Maximum	0.01 mm (0.00039 in.)
	Bush bore diameter	Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
	Bush bore diameter	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.)
Camshaft	Thrust clearance	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 HEAD

Connecting rod thrust clearance		Standard	0.25 to 0.40 mm (0.00984 to 0.0158 in.)
Connecting rod thrust clearance		Maximum	0.50 mm (0.0197 in.)
Connecting rod oil clearance		Standard	0.026 to 0.046 mm (0.00102 to 0.00181 in.)
Connecting rod oil clearance		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.)
Cylinder block warpage		Maximum	0.07 mm (0.00276 in.)
Cylinder bore diameter		Reference value (New parts)	83.000 to 83.012 mm (3.2677 to 3.2682 in.)
Cylinder bore diameter		Maximum	83.13 mm (3.27 in.)
Piston diameter		Distance	14.3 mm (0.563 in.)
		Reference value (New parts)	82.960 to 82.970 mm (3.2661 to 3.2665 in.)
		Minimum	82.846 mm (3.2616 in.)
Piston oil clearance		Reference value (New parts)	0.030 to 0.052 mm (0.00118 to 0.00205 in.)
Piston oil clearance		Maximum	0.072 mm (0.00284 in.)
Piston ring groove clearance		No. 1	0.020 to 0.070 mm (0.00079 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 (0.00079 to 0.00276 in.)
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.)
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 (-0.00008 to 0.00016 in.)
Piston pin oil clearance		Maximum	0.015 mm (0.00059 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 (0.00020 to 0.00043 in.)
Connecting rod bushing oil clearance		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.)
	No. 1	Maximum	0.50 mm (0.0197 in.)
	No. 2	Standard	0.35 to 0.40 mm (0.01378 to 0.01575 in.)
	No. 2	Maximum	0.80 mm (0.0315 in.)
	Oil	Standard	0.10 to 0.20 mm (0.00394 to 0.0787 in.)
	Oil	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.)
Connecting rod bolt diameter		Minimum	7.0 mm (0.276 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.)
Crank main journal	Taper and out-of-round	Maximum	0.02 mm (0.00079 in.)
Crank pin	Crank pin diameter	Standard	47.992 to 48.000 mm (1.889 to 1.890 in.)
Crank pin	Taper and out-of-round	Maximum	0.02 mm (0.00079 in.)
Crankshaft oil clearance		Standard	0.026 to 0.047 mm (0.00102 to 0.00185 in.)
Crankshaft oil clearance		Maximum	0.050 mm (0.00197 in.)
Standard Cylinder Block Main Journal Bore Diameter		Mark 00	66.000 mm (2.59842 in.)
		Mark 01	66.001 mm (2.59846 in.)
		Mark 02	66.002 mm (2.59850 in.)
		Mark 03	66.003 mm (2.59854 in.)
		Mark 04	66.004 mm (2.59858 in.)
		Mark 05	66.005 mm (2.59862 in.)
		Mark 06	66.006 mm (2.59866 in.)
		Mark 07	66.007 mm (2.59870 in.)
		Mark 08	66.008 mm (2.59874 in.)
		Mark 09	66.009 mm (2.59877 in.)
		Mark 10	66.010 mm (2.59881 in.)
		Mark 11	66.011 mm (2.59885 in.)
		Mark 12	66.012 mm (2.59889 in.)
		Mark 13	66.013 mm (2.59893 in.)
		Mark 14	66.014 mm (2.59897 in.)
		Mark 15	66.015 mm (2.59901 in.)
		Mark 16	66.016 mm (2.59905 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 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	2.478 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 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	2.503 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.)
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.)

CYLINDER BLOCK

Engine Mechanical (Service Specifications): Other Lexus IS III

SERVICE DATA [04/2013 - ]

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