Engine Mechanical (Service Specifications) (2ZR-FE): Other

DRIVE BELT

Deflection	New Belt	7.0 to 8.2 mm (0.276 to 0.323 in.)
Deflection	Used Belt	7.6 to 10.0 mm (0.299 to 0.394 in.)
Tension	New Belt	700 to 800 N (71 to 82 kgf, 157.4 to 179.8 lbf)
Tension	Used Belt	550 to 750 N (56 to 76 kgf, 123.6 to 168.6 lbf)

DRIVE BELT

ENGINE UNIT

Timing 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	Diameter (with Chain)		Minimum	48.2 mm (1.898 in.)
Oil pump drive shaft gear	Diameter (with Chain)		Minimum	48.2 mm (1.898 in.)
Camshaft timing gear assembly	Diameter (with Chain)		Minimum	96.8 mm (3.811 in.)
Camshaft timing exhaust gear assembly	Diameter (with Chain)		Minimum	96.8 mm (3.811 in.)
Crankshaft timing sprocket	Diameter (with Chain)		Minimum	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	Runout		Maximum	0.04 mm (0.00157 in.)
	Cam lobe height		Standard	42.816 to 42.916 mm (1.6857 to 1.6896 in.)
	Cam lobe height		Minimum	42.666 mm (1.6798 in.)
	Journal diameter	No. 1 journal	Standard	34.449 to 34.465 mm (1.35626 to 1.35689 in.)
	Journal diameter	Other	Standard	22.949 to 22.965 mm (0.90350 to 0.90413 in.)
No. 2 camshaft	Runout		Maximum	0.04 mm (0.00157 in.)
	Cam lobe height		Standard	44.336 to 44.436 mm (1.7455 to 1.7494 in.)
	Cam lobe height		Minimum	44.186 mm (1.7396 in.)
	Journal diameter	No. 1 journal	Standard	34.449 to 34.465 mm (1.35626 to 1.35689 in.)
	Journal diameter	Other	Standard	22.949 to 22.965 mm (0.90350 to 0.90413 in.)
Cylinder head set bolt	Length		Standard	146.8 to 148.2 mm (5.7795 to 5.8346 in.)
	Length		Maximum	149.2 mm (5.874 in.)
	Diameter		Standard	9.77 to 9.96 mm (0.3846 to 0.3921 in.)
	Diameter		Minimum	9.4 mm (0.3701 in.)
Exhaust manifold	Warpage		Maximum	0.7 mm (0.0276 in.)
Ring pin for stiffening crankcase assembly	Protrusion		Standard	3.0 mm (0.118 in.)

ENGINE UNIT

CYLINDER HEAD

Cylinder head sub-assembly	Warpage	Cylinder block sub-assembly side		0.05 mm (0.00197 in.)
		Intake manifold side		0.10 mm (0.00394 in.)
		Exhaust manifold side		0.10 mm (0.00394 in.)
Camshaft	Thrust clearance	Intake	Standard	0.06 to 0.155 mm (0.00236 to 0.00610 in.)
		Intake	Maximum	0.17 mm (0.00669 in.)
		Exhaust	Standard	0.06 to 0.155 mm (0.00236 to 0.00610 in.)
		Exhaust	Maximum	0.17 mm (0.00669 in.)
	Oil clearance	No. 1 journal	Standard	0.030 to 0.063 mm (0.00118 to 0.00248 in.)
		No. 1 journal	Maximum	0.085 mm (0.00335 in.)
		Other journals	Standard	0.035 to 0.072 mm (0.00138 to 0.00283 in.)
		Other journals	Maximum	0.09 mm (0.00354 in.)
Inner compression spring	Free length		Standard	52.90 mm (2.08 in.) or 53.87 mm (2.12 in.)
Inner compression spring	Deviation		Maximum	1.0 mm (0.0394 in.)
Intake valve	Overall length		Standard	109.34 mm (4.3047 in.)
	Overall length		Minimum	108.84 mm (4.2850 in.)
	Valve stem diameter		Standard	5.470 to 5.485 mm (0.2154 to 0.2159 in.)
	Margin thickness		Standard	1.0 mm (0.0394 in.)
	Margin thickness		Minimum	0.5 mm (0.0197 in.)
Exhaust valve	Overall length		Standard	109.34 mm (4.3047 in.)
	Overall length		Minimum	108.84 mm (4.2850 in.)
	Valve stem diameter		Standard	5.470 to 5.485 mm (0.2154 to 0.2159 in.)
	Margin thickness		Standard	1.0 mm (0.0394 in.)
	Margin thickness		Minimum	0.5 mm (0.0197 in.)
Valve guide bush	Bush inside diameter		Standard	5.510 to 5.530 mm (0.2169 to 0.2177 in.)
	Oil clearance	Intake	Standard	0.025 to 0.060 mm (0.000984 to 0.00236 in.)
		Exhaust	Standard	0.030 to 0.065 mm (0.00118 to 0.00256 in.)
		Intake	Maximum	0.080 mm (0.00315 in.)
		Exhaust	Maximum	0.085 mm (0.00335 in.)
	Bush bore diameter for cylinder head sub-assembly	STD	Standard	10.333 to 10.344 mm (0.4068 to 0.4072 in.)
	Bush bore diameter for cylinder head sub-assembly	O/S 0.05	Standard	10.383 to 10.394 mm (0.4088 to 0.4092 in.)
	Protrusion height	Intake	Standard	9.9 to 10.3 mm (0.390 to 0.406 in.)
	Protrusion height	Exhaust	Standard	11.15 to 11.55 mm (0.439 to 0.455 in.)
Ring pin for cylinder head cover sub-assembly	Protrusion height		Standard	6.5 to 7.5 mm (0.256 to 0.295 in.)
Spark plug tube	Application width		Standard	1.0 to 3.0 mm (0.0394 to 0.118 in.)
Spark plug tube	Protrusion height		Standard	122 mm (4.80 in.)

CYLINDER HEAD

CYLINDER BLOCK

Connecting rod thrust clearance		Standard	0.160 to 0.342 mm (0.00630 to 0.0135 in.)
Connecting rod thrust clearance		Maximum	0.342 mm (0.0135 in.)
Connecting rod oil clearance		Standard	0.014 to 0.038 mm (0.000551 to 0.00150 in.)
Connecting rod oil clearance		Maximum	0.070 mm (0.00276 in.)
Standard connecting rod large end bore diameter		Mark 1	47.000 to 47.008 mm (1.85039 to 1.85070 in.)
		Mark 2	47.009 to 47.016 mm (1.85074 to 1.85102 in.)
		Mark 3	47.017 to 47.024 mm (1.85106 to 1.85133 in.)
Standard connecting rod bearing thickness		Mark 1	1.489 to 1.493 mm (0.058621 to 0.058779 in.)
		Mark 2	1.494 to 1.497 mm (0.058819 to 0.058937 in.)
		Mark 3	1.498 to 1.501 mm (0.058976 to 0.059094 in.)
Crank pin diameter		Standard	43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Cylinder block sub-assembly warpage		Maximum	0.05 mm (0.00197 in.)
Cylinder bore diameter (New parts)		Standard	80.500 to 80.513 mm (3.1693 to 3.1698 in.)
Cylinder bore diameter (New parts)		Maximum	80.633 mm (3.1745 in.)
Piston diameter (New parts)		Reference	80.471 to 80.491 mm (3.16814 to 3.16893 in.)
Piston oil clearance (New parts)		Reference	0.009 to 0.042 mm (0.000354 to 0.00165 in.)
Piston oil clearance (New parts)		Maximum	0.08 mm (0.00315 in.)
Piston ring groove clearance	No. 1 compression ring	Standard	0.03 to 0.07 mm (0.00118 to 0.00276 in.)
	No. 2 compression ring	Standard	0.02 to 0.06 mm (0.000787 to 0.00236 in.)
	Oil ring	Standard	0.02 to 0.065 mm (0.000787 to 0.00256 in.)
Piston ring end gap	No. 1 compression ring	Standard	0.20 to 0.30 mm (0.00787 to 0.0118 in.)
	No. 1 compression ring	Maximum	0.50 mm (0.0197 in.)
	No. 2 compression ring	Standard	0.30 to 0.50 mm (0.0118 to 0.0197 in.)
	No. 2 compression ring	Maximum	0.70 mm (0.0276 in.)
	Oil ring	Standard	0.10 to 0.40 mm (0.00394 to 0.0157 in.)
	Oil ring	Maximum	0.70 mm (0.0276 in.)
Standard piston pin bore diameter		Mark A	20.006 to 20.009 mm (0.78764 to 0.78775 in.)
		Mark B	20.010 to 20.012 mm (0.78779 to 0.78787 in.)
		Mark C	20.013 to 20.015 mm (0.78791 to 0.78799 in.)
Standard piston pin diameter		Mark A	20.004 to 20.007 mm (0.78756 to 0.78768 in.)
		Mark B	20.008 to 20.010 mm (0.78771 to 0.78779 in.)
		Mark C	20.011 to 20.013 mm (0.78783 to 0.78791 in.)
Standard connecting rod small end bore diameter		Mark A	20.012 to 20.015 mm (0.78787 to 0.78799 in.)
		Mark B	20.016 to 20.018 mm (0.78803 to 0.78811 in.)
		Mark C	20.019 to 20.021 mm (0.78815 to 0.78823 in.)
Piston pin oil clearance	Piston side	Standard	0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)
	Piston side	Maximum	0.008 mm (0.000315 in.)
	Connecting rod side	Standard	0.005 to 0.011 mm (0.000197 to 0.000433 in.)
	Connecting rod side	Maximum	0.014 mm (0.000551 in.)
Connecting rod misalignment		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.)
Crankshaft runout		Maximum	0.03 mm (0.00118 in.)
Standard crankshaft journal diameter (Reference)		Mark 0	47.999 to 48.000 mm (1.88972 to 1.88976 in.)
		Mark 1	47.997 to 47.998 mm (1.88964 to 1.88968 in.)
		Mark 2	47.995 to 47.996 mm (1.88956 to 1.88960 in.)
		Mark 3	47.993 to 47.994 mm (1.88948 to 1.88952 in.)
		Mark 4	47.991 to 47.992 mm (1.88941 to 1.88945 in.)
		Mark 5	47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Crank pin diameter		Standard	43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Crank pin taper and out-of-round		Maximum	0.004 mm (0.000157 in.)
Crankshaft thrust clearance		Standard	0.04 to 0.14 mm (0.00157 to 0.00551 in.)
Crankshaft thrust clearance		Maximum	0.18 mm (0.00709 in.)
Crankshaft oil clearance		Standard	0.016 to 0.039 mm (0.000630 to 0.00154 in.)
Crankshaft oil clearance		Maximum	0.050 mm (0.00197 in.)
Standard cylinder block journal bore diameter		Mark 0	52.000 to 52.002 mm (2.04724 to 2.04732 in.)
		Mark 1	52.003 to 52.004 mm (2.04736 to 2.04740 in.)
		Mark 2	52.005 to 52.006 mm (2.04744 to 2.04748 in.)
		Mark 3	52.007 to 52.009 mm (2.04752 to 2.04759 in.)
		Mark 4	52.010 to 52.011 mm (2.04763 to 2.04767 in.)
		Mark 5	52.012 to 52.013 mm (2.04771 to 2.04775 in.)
		Mark 6	52.014 to 52.016 mm (2.04779 to 2.04787 in.)
Standard bearing center wall thickness		Mark 1	1.994 to 1.997 mm (0.07850 to 0.07862 in.)
		Mark 2	1.998 to 2.000 mm (0.07866 to 0.07874 in.)
		Mark 3	2.001 to 2.003 mm (0.07878 to 0.07886 in.)
		Mark 4	2.004 to 2.006 mm (0.07890 to 0.07898 in.)
Crankshaft bearing cap set bolt length		Standard	84.3 to 85.7 mm (3.3189 to 3.3740 in.)
Crankshaft bearing cap set bolt length		Maximum	86.7 mm (3.4134 in.)
Crankshaft bearing cap set bolt diameter		Distance	55.0 mm (2.17 in.)
		Standard	9.77 to 9.96 mm (0.3846 to 0.3921 in.)
		Minimum	9.1 mm (0.3583 in.)
Connecting rod bolt diameter		Standard	6.6 to 6.7 mm (0.2598 to 0.2638 in.)
Connecting rod bolt diameter		Maximum	6.4 mm (0.2520 in.)
Cylinder block ring pin	Protrusion	Standard	7.5 to 8.5 mm (0.295 to 0.335 in.)
Straight pin for cylinder block sub-assembly protrusion	Protrusion	Pin A	18.5 to 19.5 mm (0.728 to 0.768 in.)
		Pin B	5.0 to 7.0 mm (0.197 to 0.276 in.)
		Pin C	11 to 13 mm (0.433 to 0.512 in.)
		Pin D	8.0 to 10.0 mm (0.315 to 0.394 in.)
		Pin E	5.0 to 6.0 mm (0.197 to 0.236 in.)

CYLINDER BLOCK

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Fan belt	Bolt A	Torque: 25 N*m (	Torque: 255 kgf*cm	Torque: 18 ft.*lbf)
Fan belt	Bolt B	Torque: 43 N*m (	Torque: 438 kgf*cm	Torque: 32 ft.*lbf)
Fan belt adjusting bar x Cylinder head sub-assembly		Torque: 25 N*m (	Torque: 255 kgf*cm	Torque: 18 ft.*lbf)
Fan belt adjusting bar x Generator assembly		Torque: 25 N*m (	Torque: 255 kgf*cm	Torque: 18 ft.*lbf)

DRIVE BELT

CAMSHAFT

Part Tightened		N*m	Kgf*cm	Ft.*lbf	In.*lbf
Camshaft housing x Camshaft bearing cap		Torque: 27 N*m (	Torque: 275 kgf*cm	Torque: 20 ft.*lbf)
Camshaft timing exhaust gear assembly x Camshaft	With SST	Torque: 39 N*m (	Torque: 398 kgf*cm	Torque: 29 ft.*lbf)
Camshaft timing exhaust gear assembly x Camshaft	Without SST	Torque: 54 N*m (	Torque: 551 kgf*cm	Torque: 40 ft.*lbf)
Camshaft timing gear assembly x Camshaft		Torque: 54 N*m (	Torque: 551 kgf*cm	Torque: 40 ft.*lbf)
Camshaft bearing cap x Cylinder head sub-assembly		Torque: 27 N*m (	Torque: 275 kgf*cm	Torque: 20 ft.*lbf)
Camshaft bearing cap x Camshaft housing		Torque: 16 N*m (	Torque: 163 kgf*cm	Torque: 12 ft.*lbf)
Air tube x Cylinder head cover sub-assembly		Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)
No. 2 chain vibration damper x Cylinder head sub-assembly	With SST	Torque: 5.5 N*m (	Torque: 56 kgf*cm		Torque: 49 in.*lbf)
No. 2 chain vibration damper x Cylinder head sub-assembly	Without SST	Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)
Engine wire x Cylinder head cover sub-assembly		Torque: 8.4 N*m (	Torque: 86 kgf*cm		Torque: 74 in.*lbf)

CAMSHAFT

CYLINDER HEAD GASKET

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Cylinder head sub-assembly x Cylinder block sub-assembly	1st	Torque: 49 N*m (	Torque: 500 kgf*cm	Torque: 36 ft.*lbf)
	2nd	Turn 90°
	3rd	Turn 45°

CYLINDER HEAD GASKET

FRONT CRANKSAFT OILSEAL

Part Tightened				N*m	Kgf*cm	Ft.*lbf
Crankshaft pulley x Crankshaft				Torque: 190 N*m (	Torque: 1937 kgf*cm	Torque: 140 ft.*lbf)

FRONT CRANKSAFT OILSEAL

REAR CRANKSHAFT OIL SEAL

Part Tightened				N*m	Kgf*cm	Ft.*lbf
Flywheel sub-assembly x Crankshaft				Torque: 49 N*m (	Torque: 500 kgf*cm	Torque: 36 ft.*lbf)
Drive plate and ring gear sub-assembly x Crankshaft				Torque: 88 N*m (	Torque: 897 kgf*cm	Torque: 65 ft.*lbf)

REAR CRANKSHAFT OIL SEAL

Part Tightened		N*m	Kgf*cm	Ft.*lbf	In.*lbf
Stiffening crankcase stud bolt x Cylinder block sub-assembly		Torque: 5.0 N*m (	Torque: 51 kgf*cm		Torque: 44 in.*lbf)
Stiffening crankcase assembly x Cylinder block sub-assebmly		Torque: 21 N*m (	Torque: 214 kgf*cm	Torque: 15 ft.*lbf)
Oil pan drain plug x No. 2 oil pan sub-assembly		Torque: 37 N*m (	Torque: 377 kgf*cm	Torque: 27 ft.*lbf)
No. 1 taper screw plug x Cylinder block	Bolt A	Torque: 25 N*m (	Torque: 255 kgf*cm	Torque: 18 ft.*lbf)
No. 1 taper screw plug x Cylinder block	Bolt B	Torque: 43 N*m (	Torque: 438 kgf*cm	Torque: 32 ft.*lbf)
Camshaft housing sub-assembly x Camshaft bearing cap		Torque: 16 N*m (	Torque: 163 kgf*cm	Torque: 12 ft.*lbf)
Camshaft housing sub-assembly x Cylinder head sub-assembly		Torque: 27 N*m (	Torque: 275 kgf*cm	Torque: 20 ft.*lbf)
Camshaft timing exhaust gear assembly x Camshaft		Torque: 54 N*m (	Torque: 551 kgf*cm	Torque: 40 ft.*lbf)
Camshaft timing gear assembly x Camshaft		Torque: 54 N*m (	Torque: 551 kgf*cm	Torque: 40 ft.*lbf)
No. 1 chain vibration damper x Cylinder block sub-assembly		Torque: 21 N*m (	Torque: 214 kgf*cm	Torque: 15 ft.*lbf)
No. 2 chain vibration damper x Camshaft bearing cap		Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)
No. 1 generator bracket x Cylinder block sub-assembly		Torque: 24 N*m (	Torque: 245 kgf*cm	Torque: 18 ft.*lbf)
Stud bolt x Water inlet housing		Torque: 5.0 N*m (	Torque: 51 kgf*cm		Torque: 44 in.*lbf)
Water inlet housing x Timing chain cover sub-assembly		Torque: 21 N*m (	Torque: 214 kgf*cm	Torque: 15 ft.*lbf)
No. 1 chain tensioner assembly x Timing chain cover sub-assembly		Torque: 12 N*m (	Torque: 122 kgf*cm	Torque: 9 ft.*lbf)
Cylinder head cover sub-assembly x Cylinder head sub-assembly		Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)
Engine cover joint x Cylinder head cover sub-assembly		Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)
No. 1 Water by-pass pipe x Cylinder block sub-assembly		Torque: 21 N*m (	Torque: 214 kgf*cm	Torque: 15 ft.*lbf)
Oil level dipstick guide x Cylinder block sub-assembly		Torque: 21 N*m (	Torque: 214 kgf*cm	Torque: 15 ft.*lbf)

ENGINE UNIT

Part Tightened		N*m	Kgf*cm	Ft.*lbf	In.*lbf
Stud bolt x Cylinder head sub-assembly	Bolt A	Torque: 9.5 N*m (	Torque: 97 kgf*cm		Torque: 84 in.*lbf)
Stud bolt x Cylinder head sub-assembly	Bolt B	Torque: 9.5 N*m (	Torque: 97 kgf*cm		Torque: 84 in.*lbf)
No. 2 straight screw plug x Cylinder head sub-assembly		Torque: 44 N*m (	Torque: 449 kgf*cm	Torque: 32 ft.*lbf)

CYLINDER HEAD

Part Tightened		N*m	Kgf*cm	Ft.*lbf	In.*lbf
Connecting rod cap x Connecting rod	1st	Torque: 20 N*m (	Torque: 204 kgf*cm	Torque: 15 ft.*lbf)
Connecting rod cap x Connecting rod	2nd	Turn 90°
Stud bolt x Cylinder block sub-assembly		Torque: 5.0 N*m (	Torque: 51 kgf*cm		Torque: 44 in.*lbf)
No. 1 oil nozzle sub-assembly x Cylinder block sub-assembly		Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)
Crankshaft bearing cap x Cylinder block sub-assembly	1st	Torque: 40 N*m (	Torque: 408 kgf*cm	Torque: 30 ft.*lbf)
Crankshaft bearing cap x Cylinder block sub-assembly	2nd	Turn 90°
No. 1 ventilation case x Cylinder block sub-assembly		Torque: 10 N*m (	Torque: 102 kgf*cm	Torque: 7 ft.*lbf)

CYLINDER BLOCK

Engine Mechanical (Service Specifications) (2ZR-FE): Other Toyota Corolla XI

DRIVE BELT

ENGINE UNIT

CYLINDER HEAD

CYLINDER BLOCK

CAMSHAFT

CYLINDER HEAD GASKET

FRONT CRANKSAFT OILSEAL

REAR CRANKSHAFT OIL SEAL

More articles — Engine Mechanical (Service Specifications) (2ZR-FE)

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