SERVICE DATA
| Ignition timing | Terminals TC and CG of DLC3 connected | 8 - 12° BTDC @ idle (Transmission in neutral position) |
|---|---|---|
| Idle speed | 650 - 750 r/min | |
| Compression | Compression pressure | 1324 kPa (13.5 kgf/cm 2 , 192 psi) or more |
| Minimum pressure | 981 kPa (10 kgf/cm 2 , 142 psi) | |
| Difference between each cylinder | 98 kPa (1.0 kgf/cm 2 , 14 psi) | |
| Valve clearance | ||
| Intake | (cold) | 0.15 - 0.25 mm (0.006 - 0.010 in.) |
| Exhaust | 0.25 - 0.35 mm (0.010 - 0.014 in.) | |
| Cylinder head | ||
| Warpage | Maximum | 0.10 mm (0.039 in.) |
| Valve seat | ||
| Refacing angle | 30°, 45°, 60° | |
| Contacting angle | 45° | |
| Contacting width | 1.0 - 1.4 mm (0.039 - 0.055 in.) | |
| Valve guide bushing bore diameter | STD | 10.285 - 10.306 mm (0.4049 - 0.4057 in.) |
| O/S 0.05 | 10.335 - 10.356 mm (0.4069 - 0.4077 in.) | |
| Cylinder head seat bolt thread inside diameter | STD | 9.810 - 9.960 mm (0.3862 - 0.3921 in.) |
| Minimum | 9.70 mm (0.3819 in.) | |
| Protrusion height | Intake | 9.2 - 9.8 mm (0.362 - 0.386 in.) |
| Exhaust | 8.2 - 8.8 mm (0.323 - 0.346 in.) | |
| Valve guide bushing | ||
| Inside diameter | 5.510 - 5.530 mm (0.2169 - 0.2374 in.) | |
| Outside diameter (for repair part) | STD | 10.285 - 10.306 mm (0.4049 - 0.4057 in.) |
| O/S 0.05 | 10.335 - 10.356 mm (0.4069 - 0.4077 in.) | |
| Valve | ||
| Valve overall length | STD Intake | 95.05 mm (3.7421 in.) |
| Exhaust | 95.10 mm (3.7441 in.) | |
| Minimum Intake | 94.55 mm (3.7224 in.) | |
| Exhaust | 94.60 mm (3.7244 in.) | |
| Valve face angle | 44.5° | |
| Stem diameter | Intake | 5.470 - 5.485 mm (0.2154 - 0.2159 in.) |
| Exhaust | 5.465 - 5.480 mm (0.2152 - 0.2157 in.) | |
| Stem oil clearance | STD Intake | 0.025 - 0.060 mm (0.0010 - 0.0024 in.) |
| Exhaust | 0.030 - 0.065 mm (0.0012 - 0.0026 in.) | |
| Maximum Intake | 0.08 mm (0.031 in.) | |
| Exhaust | 0.10 mm (0.039 in.) | |
| Margin thickness | STD IN | 1.25 mm (0.049 in.) |
| EX | 1.4 mm (0.055 in.) | |
| Minimum | 0.5 mm (0.020 in.) | |
| Valve spring | ||
| Deviation | Maximum | 2.0 mm (0.079 in.) |
| Free length | 54.1 mm (2.130 in.) | |
| Installed tension at 35.0 mm (1.378 in.) | 210 - 226 N (21.4 - 23.0 kgf.cm, 47.2 - 50.7 lbf) | |
| Valve lifter | ||
| Lifter diameter | 30.968 - 30.976 mm (1.2192 - 2.2195 in.) | |
| Lifter bore diameter | 31.000 - 31.016 mm (1.2205 - 1.2211 in.) | |
| Oil clearance | STD | 0.024 - 0.050 mm (0.0009 - 0.0020 in.) |
| Maximum | 0.07 mm (0.0028 in.) | |
| Camshaft | ||
| Thrust clearance | STD Intake | 0.040 - 0.090 mm (0.0016 - 0.0035 in.) |
| Exhaust | 0.030 - 0.075 mm (0.0012 - 0.0030 in.) | |
| Minimum Intake | 0.12 mm (0.0047 in.) | |
| Exhaust | 0.10 mm (0.0039 in.) | |
| Journal oil diameter | STD | 0.030 - 0.071 mm (0.012 - 0.0028 in.) |
| Maximum | 0.10 mm (0.039 in.) | |
| Journal diameter | 26.954 - 26.970 mm (1.0612 - 1.0618 in.) | |
| Circuit runout | Maximum | 0.08 mm (0.031 in.) |
| Cam lobe height | STD Intake | 41.94 - 42.04 mm (1.6512 - 1.6551 in.) |
| Exhaust | 41.96 - 42.06 mm (1.6520 - 1.6559 in.) | |
| Minimum Intake | 41.79 mm (1.6453 in.) | |
| Exhaust | 41.81 mm (1.6461 in.) | |
| Camshaft gear backlash | STD | 0.020 - 0.200 mm (0.0008 - 0.0079 in.) |
| Maximum | 0.30 mm (0.0118 in.) | |
| Camshaft gear bolt washer end free distance | 18.2 - 18.8 mm (0.712 - 0.740 in.) | |
| Cylinder block | ||
| Cylinder head surface warpage | Maximum | 0.07 mm (0.0028 in.) |
| Cylinder bore diameter | STD Mark 1 | 94.002 - 94.010 mm (3.7009 - 3.7012 in.) |
| Mark 2 | 94.010 - 94.023 mm (3.7012 - 3.7017 in.) | |
| Mark 3 | 94.023 - 94.031 mm (3.7017 - 3.7020 in.) | |
| Maximum STD | 94.231 mm (3.7099 in.) | |
| O/S 0.5 | 94.731 mm (3.7296 in.) | |
| Main bearing cap bolt tension portion diameter | STD | 10.760 - 10.970 mm (0.4236 - 0.4319 in.) |
| Minimum | 10.40 mm (0.4094 in.) | |
| Piston and piston ring | ||
| Piston diameter | STD Mark 1 | 93.902 - 93.912 mm (3.6969 - 3.6973 in.) |
| Mark 2 | 93.912 - 93.920 mm (3.6973 - 3.6976 in.) | |
| Mark 3 | 93.920 - 93.930 mm (3.6976 - 3.6980 in.) | |
| O/S 0.5 | 94.402 - 94.430 mm (3.7168 - 3.7177 in.) | |
| Piston oil clearance | STD | 0.090 - 0.111 mm (0.0035 - 0.0044 in.) |
| Maximum | 0.13 mm (0.0051 in.) | |
| Piston ring groove clearance | No. 1 | 0.030 - 0.080 mm (0.0012 - 0.0031 in.) |
| No. 2 | 0.030 - 0.070 mm (0.0012 - 0.0028 in.) | |
| Piston ring end gap | No. 1 | 0.300 - 0.400 mm (0.0118 - 0.0158 in.) |
| No. 2 | 0.400 - 0.550 mm (0.0157 - 0.0217 in.) | |
| Oil | 0.130 - 0.380 mm (0.0051 - 0.0150 in.) | |
| Maximum No. 1 | 1.10 mm (0.0433 in.) | |
| No. 2 | 1.20 mm (0.0472 in.) | |
| Oil | 1.15 mm (0.0453 in.) | |
| Connecting rod | ||
| Thrust clearance | STD | 0.160 - 0.290 mm (0.0063 - 0.0138 in.) |
| Maximum | 0.35 mm (0.0138 in.) | |
| Connecting rod thickness | 22.880 - 22.920 mm (0.9008 - 0.9024 in.) | |
| Connecting rod oil clearance | STD | 0.027 - 0.053 mm (0.0011 - 0.0021 in.) |
| Maximum | 0.065 mm (0.0026 in.) | |
| Connecting rod bearing center wall thickness | ||
| Mark 2 | 1.484 - 1.487 mm (0.0584 - 0.0585 in.) | |
| Mark 3 | 1.487 - 1.490 mm (0.0585 - 0.0587 in.) | |
| Mark 4 | 1.490 - 1.493 mm (0.0587 - 0.0588 in.) | |
| Mark 5 | 1.493 - 1.496 mm (0.0588 - 0.0589 in.) | |
| Mark 6 | 1.496 - 1.499 mm (0.0589 - 0.0590 in.) | |
| Mark 7 | 1.499 - 1.502 mm (0.0590 - 0.0591 in.) | |
| Rod bend | Maximum per 100 mm (3.94 in.) | 0.05 mm (0.0020 in.) |
| Rod twist | Maximum per 100 mm (3.94 in.) | 0.15 mm (0.0059 in.) |
| Bushing inside diameter | 22.005 - 22.014 mm (0.8663 - 0.8667 in.) | |
| Piston pin diameter | 21.997 - 22.006 mm (0.8660 - 0.8664 in.) | |
| Bushing oil clearance | STD | 0.005 - 0.011 mm (0.0002 - 0.0004 in.) |
| Maximum | 0.05 mm (0.0020 in.) | |
| Connecting rod bolt tension portion diameter | STD | 7.200 - 7.300 mm (0.2835 - 0.2874 in.) |
| Maximum | 7.00 mm (0.2756 in.) | |
| Crankshaft | ||
| Thrust clearance | STD | 0.020 - 0.220 mm (0.0008 - 0.0087 in.) |
| Maximum | 0.30 mm (0.0118 in.) | |
| Thrust washer thickness | STD | 2.440 - 2.490 mm (0.0961 - 0.0980 in.) |
| U/S 0.125 | 2.503 - 2.553 mm (0.0985 - 0.1005 in.) | |
| Main journal bore diameter on cylinder block | 72.000 - 72.016 mm (2.8347 - 2.8353 in.) | |
| Main journal oil clearance | No. 1 and No. 5 STD | 0.028 - 0.046 mm (0.0011 - 0.0018 in.) |
| Others STD | 0.040 - 0.058 mm (0.0016 - 0.0023 in.) | |
| No. 1 and No. 5 Maximum | 0.065 mm (0.0026 in.) | |
| Others Maximum | 0.065 mm (0.0026 in.) | |
| Main journal diameter | 66.988 - 67.000 mm (2.6373 - 2.6378 in.) | |
| Main bearing center wall thickness | No. 1 and No. 5 Mark 3 | 2.487 - 2.490 mm (0.0979 - 0.0980 in.) |
| Mark 4 | 2.490 - 2.493 mm (0.0980 - 0.0982 in.) | |
| Mark 5 | 2.493 - 2.496 mm (0.0982 - 0.0983 in.) | |
| Mark 6 | 2.496 - 2.499 mm (0.0983 - 0.0984 in.) | |
| Mark 7 | 2.499 - 2.502 mm (0.0984 - 0.0985 in.) | |
| Other Mark 1 | 2.481 - 2.484 mm (0.0977 - 0.0978 in.) | |
| Mark 2 | 2.484 - 2.487 mm (0.0978 - 0.0979 in.) | |
| Mark 3 | 2.487 - 2.490 mm (0.0979 - 0.0980 in.) | |
| Mark 4 | 2.490 - 2.493 mm (0.0980 - 0.0981 in.) | |
| Mark 5 | 2.493 - 2.496 mm (0.0981 - 0.0983 in.) | |
| Crank pin diameter | 51.982 - 52.000 mm (2.0465 - 2.0472 in.) | |
| Circle runout | Maximum | 0.08 mm (0.0031 in.) |
| Main journal taper and out-of-round | Maximum | 0.02 mm (0.0008 in.) |
| Crank pin taper and out-of-round | Maximum | 0.02 mm (0.0008 in.) |
Engine Mechanical (2UZ-FE) Service Specifications