Service Data

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1GR-FE:

SERVICE DATA SPECIFICATION (ENGINE MECHANICAL-1GR-FE)

Ignition timing	Terminals TC and CG of DLC3 connected	10 +/- 2° BTDC idle (Transmission in neutral)
-	Terminals TC and CG of DLC3 disconnected	7 to 24 +/- BTDC idle (Transmission in neutral)
Idle speed		700 +/- 50 rpm (Transmission in neutral)
Compression	Compression pressure	1.3 MPa (13.3 kgf/cm² , 189 psi) or more
-	Minimum pressure	1.0 MPa (10.2 kgf/cm² , 145 psi)
-	Difference between each cylinder	0.1 MPa (1.0 kgf/cm² , 15 psi) or less
Valve clearance		-
Intake	(cold)	0.15 to 0.25 mm (0.006 to 0.010 in.)
Exhaust		0.29 to 0.39 mm (0.011 to 0.015 in.)
Intake manifold		-
Intake air surge tank side warpage	Maximum	0.8 mm (0.031 in.)
Cylinder head side warpage		0.2 mm (0.008 in.)
Exhaust manifold		-
Warpage	Maximum	0.7 mm (0.028 in.)
Camshaft timing gear assy		-
Diameter (w/ chain)	Large gear	115.5 mm (4.547 in.)
-	Small gear	73.1 mm (2.878 in.)
Camshaft timing gear or sprocket		-
Diameter (w/ chain)		73.1 mm (2.878 in.)
Crankshaft timing gear or sprocket		-
Diameter (w/ chain)		61.0 mm (2.402 in.)
Idle gear No.1		-
Diameter (w/ chain)		61.0 mm (2.402 in.)
Cylinder head set bolt		-
Outside diameter	Standard	10.85 to 11.00 mm (0.4272 to 0.4331 in.)
-	Minimum	10.7 mm (0.421 in.)
Chain		-
Elongation	Maximum	146.8 mm (5.780 in.)
No.2 chain		-
Elongation	Maximum	146.8 mm (5.780 in.)
Idle gear shaft		-
Idle gear shaft diameter		22.987 to 23.000 mm (0.9050 to 0.9055 in.)
Idle gear inside diameter		23.02 to 23.03 mm (0.9063 to 0.9067 in.)
Oil clearance	Standard	0.020 to 0.043 mm (0.0008 to 0.0017 in.)
-	Maximum	0.093 mm (0.0037 in.)
Chain tensioner assy No.2		-
Worn depth	Maximum	1.0 mm (0.039 in.)
Chain tensioner assy No.3		-
Worn depth	Maximum	1.0 mm (0.039 in.)
Chain tensioner slipper		-
Worn depth	Maximum	1.0 mm (0.039 in.)
Chain vibration damper No.1		-
Worn depth	Maximum	1.0 mm (0.039 in.)
Chain vibration damper No.2		-
Worn depth	Maximum	1.0 mm (0.039 in.)
Cylinder head sub-assy		-
Warpage	Maximum	0.10 mm (0.0039 in.)
Intake valve		-
Valve stem diameter		5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Valve face angle		44.5°
Margin thickness	Standard	1.0 mm (0.039 in.)
-	Minimum	0.5 mm (0.020 in.)
Overall length	Standard	106.95 mm (4.2106 in.)
-	Minimum	106.40 mm (4.1890 in.)
Exhaust valve		-
Valve stem diameter		5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Valve face angle		44.5°
Margin thickness	Standard	1.0 mm (0.039 in.)
-	Minimum	0.5 mm (0.020 in.)
Overall length	Standard	105.80 mm (41653 in.)
-	Minimum	105.30 mm (4.1457 in.)
Inner compression spring		-
Deviation	Maximum	2.0 mm (0.079 in.)
Free length		47.80 mm (1.8819 in.)
Tension	at 33.3 mm (1.311 in.)	186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf)
Intake valve guide bush		-
Inside diameter		5.51 to 5.53 mm (0.2169 to 0.2177 in.)
Oil clearance	Standard	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
-	Maximum	0.08 mm (0.0031 in.)
Bush bore diameter		10.295 to 10.315 mm (0.4053 to 0.4061 in.)
Protrusion height		9.3 to 9.7 mm (0.366 to 0.382 in.)
Exhaust valve guide bush		-
Inside diameter		5.51 to 5.53 mm (0.2169 to 0.2177 in.)
Oil clearance	Standard	0.030 to 0.065 mm (0.0012 to 0.0026 in.)
-	Maximum	0.10 mm (0.0039 in.)
Bush bore diameter		10.295 to 10.315 mm (0.4053 to 0.4061 in.)
Protrusion height		9.3 to 9.7 mm (0.366 to 0.382 in.)
Valve lifter		-
Diameter		30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Lifter bore diameter		31.009 to 31.025 mm (1.2208 to 1.2215 in.)
Oil clearance	Standard	0.033 to 0.059 mm (0.0013 to 0.0023 in.)
-	Maximum	0.08 mm (0.0031 in.)
No.1 camshaft		-
Journal diameter	No.1 journal	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
-	Other journals	22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circuit runout	Maximum	0.06 mm (0.0024 in.)
Cam lobe height	Standard	44.168 to 44.268 mm (1.7389 to 1.7428 in.)
-	Minimum	44.018 mm (1.7330 in.)
Oil clearance	Standard No.1 journal	0.008 to 0.038 mm (0.0003 to 0.0015 in.)
-	Other journals	0.025 to 0.062 mm (0.0010 to 0.0024 in.)
-	Maximum No.1 journal	0.07 mm (0.0028 in.)
-	Other journals	0.10 mm (0.0039 in.)
Thrust clearance	Standard	0.04 to 0.09 mm (0.0016 to 0.0035 in.)
-	Maximum	0.11 mm (0.0043 in.)
No.2 camshaft		-
Journal diameter	No.1 journal	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
-	Other journals	22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circuit runout	Maximum	0.06 mm (0.0024 in.)
Cam lobe height	Standard	44.580 to 44.680 mm (1.7551 to 1.7591 in.)
-	Minimum	44.430 mm (1.7492 in.)
Oil clearance	Standard No.1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
-	Other journals	0.025 to 0.062 mm (0.0010 to 0.0024 in.)
-	Maximum	0.10 mm (0.0039 in.)
Thrust clearance	Standard	0.04 to 0.09 mm (0.0016 to 0.0035 in.)
-	Maximum	0.11 mm (0.0043 in.)
No.3 camshaft sub-assy		-
Journal diameter	No.1 journal	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
-	Other journals	22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circuit runout	Maximum	0.06 mm (0.0024 in.)
Cam lobe height	Standard	44.168 to 44.268 mm (1.7389 to 1.7428 in.)
-	Minimum	44.018 mm (1.7330 in.)
Oil clearance	Standard No.1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
-	Other journals	0.025 to 0.062 mm (0.0010 to 0.0024 in.)
-	Maximum	0.10 mm (0.0039 in.)
Thrust clearance	Standard	0.04 to 0.09 mm (0.0016 to 0.0035 in.)
-	Maximum	0.11 mm (0.0043 in.)
No.4 camshaft sub-assy		-
Journal diameter	No.1 journal	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
-	Other journals	22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Circuit runout	Maximum	0.06 mm (0.0024 in.)
Cam lobe height	Standard	44.580 to 44.680 mm (1.7551 to 1.7591 in.)
-	Minimum	44.430 mm (1.7492 in.)
Oil clearance	Standard No.1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
-	Other journals	0.025 to 0.062 mm (0.0010 to 0.0024 in.)
-	Maximum	0.10 mm (0.0039 in.)
Thrust clearance	Standard	0.04 to 0.09 mm (0.0016 to 0.0035 in.)
-	Maximum	0.11 mm (0.0043 in.)
Ring pin for cylinder head sub-assy and cylinder head LH		-
Protrusion height		2.7 to 3.3 mm (0.106 to 0.130 in.)
Straight pin for cylinder head sub-assy and cylinder head LH		-
Protrusion height (See OVERHAUL )	A	17.5 to 19.5 mm (0.689 to 0.768 in.)
-	B	7.5 to 8.5 mm (0.295 to 0.335 in.)
-	C	7.0 to 9.0 mm (0.276 to 0.354 in.)
Tight plug for cylinder head sub-assy and cylinder head LH		-
Depth		1.5 mm (0.059 in.)
Connecting rod thrust clearance	Standard	0.15 to 0.30 mm (0.0059 to 0.0118 in.)
-	Maximum	0.35 mm (0.0138 in.)
Connecting rod oil clearance	Standard	0.026 to 0.046 mm (0.0010 to 0.0018 in.)
-	Maximum	0.066 mm (0.0025 in.)
Crankshaft thrust clearance	Standard	0.04 to 0.24 mm (0.0016 to 0.0094 in.)
-	Maximum	0.30 mm (0.0118 in.)
Cylinder block warpage	Maximum	0.05 mm (0.0020 in.)
Cylinder bore diameter	Standard	94.000 to 94.012 mm (3.7008 to 3.7013 in.)
-	Maximum	94.132 mm (3.7060 in.)
Piston diameter		93.910 to 93.920 mm (3.6972 to 3.6976 in.)
Oil clearance	Standard	0.080 to 0.102 mm (0.0031 to 0.0040 in.)
-	Maximum	0.13 mm (0.0051 in.)
Connecting rod out-of alignment	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod twist	Maximum	0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
Connecting rod bushing inside diameter		22.005 to 22.014 mm (0.8663 to 0.8667 in.)
Piston pin diameter		21.997 to 22.006 mm (0.8660 to 0.8664 in.)
Oil clearance	Standard	0.005 to 0.011 mm (0.0002 to 0.0004 in.)
-	Maximum	0.050 mm (0.0020 in.)
Piston ring groove clearance	No.1	0.02 to 0.07 mm (0.0008 to 0.0028 in.)
-	No.2	0.02 to 0.06 mm (0.0008 to 0.0024 in.)
-	Oil	0.07 to 0.15 mm (0.0028 to 0.0060 in.)
Piston ring end gap	Standard No.1	0.30 to 0.40 mm (0.0118 to 0.0157 in.)
-	No.2	0.40 to 0.50 mm (0.0157 to 0.0197 in.)
-	Oil (Side rail)	0.10 to 0.40 mm (0.0039 to 0.0157 in.)
-	Maximum No.1	1.0 mm (0.039 in.)
-	No.2	1.1 mm (0.043 in.)
-	Oil (Side rail)	1.0 mm (0.039 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 bearing cap set bolt diameter	Standard	10.0 to 10.2 mm (0.393 to 0.402 in.)
Crankshaft circle runout	Maximum	0.06 mm (0.0024 in.)
Main journal diameter	-	71.988 to 72.000 mm (2.8342 to 2.8346 in.)
Main journal taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crank pin diameter	-	55.992 to 56.000 mm (2.2044 to 2.2047 in.)
Crank pin taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crankshaft oil clearance	Standard	0.018 to 0.030 mm (0.0007 to 0.0012 in.)
-	Maximum	0.046 mm (0.0018 in.)

2UZ-FE:

SERVICE DATA SPECIFICATION (ENGINE MECHANICAL-2UZ-FE)

Ignition timing	Terminals TC and CG of DLC3 connected	5 to 15° BTDC at idle (Transmission in neutral)
Idle speed		650 to 750 r/min
Compression	Compression pressure	1,373 kPa (14.0 kgf/cm² , 199 psi) or more
-	Minimum pressure	1,030 kPa (10.5 kgf/cm² , 149 psi)
-	Difference between each cylinder	98 kPa (1.0 kgf/cm² , 14 psi)
Valve clearance		-
Intake	(cold)	0.15 to 0.25 mm (0.006 to 0.010 in.)
Exhaust	(cold)	0.25 to 0.35 mm (0.010 to 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 to 1.4 mm (0.039 to 0.055 in.)
Valve guide bushing bore diameter	STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
-	O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Cylinder head seat bolt thread inside diameter	STD	9.810 to 9.960 mm (0.3862 to 0.3921 in.)
-	Minimum	9.70 mm (0.3819 in.)
Protrusion height	Intake	9.2 to 9.8 mm (0.362 to 0.386 in.)
-	Exhaust	8.2 to 8.8 mm (0.323 to 0.346 in.)
Valve guide bushing		-
Inside diameter		5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Outside diameter (for repair part)	STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
-	O/S 0.05	10.335 to 10.356 mm (0.4069 to 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 to 5.485 mm (0.2154 to 0.2159 in.)
-	Exhaust	5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Stem oil clearance	STD Intake	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
-	Exhaust	0.030 to 0.065 mm (0.0012 to 0.0026 in.)
-	Maximum Intake	0.08 mm (0.0031 in.)
-	Exhaust	0.10 mm (0.0039 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 to 226 N (21.4 to 23.0 kgf.cm, 47.2 to 50.7 lbf)
Valve lifter		-
Lifter diameter		30.968 to 30.976 mm (1.2192 to 1.2195 in.)
Lifter bore diameter		31.000 to 31.016 mm (1.2205 to 1.2211 in.)
Oil clearance	STD	0.024 to 0.050 mm (0.0009 to 0.0020 in.)
-	Maximum	0.07 mm (0.0028 in.)
Camshaft		-
Thrust clearance	STD Intake	0 to 0.040 mm (0 to 0.0016 in.)
-	Exhaust	0.030 to 0.070 mm (0.0012 to 0.0028 in.)
-	Minimum Intake	0.12 mm (0.0047 in.)
-	Exhaust	0.10 mm (0.0039 in.)
Journal oil diameter	STD	0.030 to 0.071 mm (0.012 to 0.0028 in.)
-	Maximum	0.10 mm (0.0039 in.)
Journal diameter		26.954 to 26.970 mm (1.0612 to 1.0618 in.)
Circuit runout	Maximum	0.08 mm (0.0031 in.)
Cam lobe height	STD Intake	41.94 to 42.04 mm (1.6512 to 1.6551 in.)
-	Exhaust	41.96 to 42.06 mm (1.6520 to 1.6559 in.)
-	Minimum Intake	41.79 mm (1.6453 in.)
-	Exhaust	41.81 mm (1.6461 in.)
Camshaft gear backlash	STD	0.020 to 0.200 mm (0.0008 to 0.0079 in.)
-	Maximum	0.30 mm (0.0118 in.)
Camshaft gear bolt washer end free distance		18.2 to 18.8 mm (0.717 to 0.740 in.)
Cylinder block		-
Cylinder head surface warpage	Maximum	0.07 mm (0.0028 in.)
Cylinder bore diameter	STD Mark 1	94.002 to 94.010 mm (3.7009 to 3.7012 in.)
-	Mark 2	94.010 to 94.023 mm (3.7012 to 3.7017 in.)
-	Mark 3	94.023 to 94.031 mm (3.7017 to 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 to 10.970 mm (0.4236 to 0.4319 in.)
-	Minimum	10.40 mm (0.4094 in.)
Piston and piston ring		-
Piston diameter	STD Mark 1	93.902 to 93.912 mm (3.6969 to 3.6973 in.)
-	Mark 2	93.912 to 93.920 mm (3.6973 to 3.6976 in.)
-	Mark 3	93.920 to 93.930 mm (3.6976 to 3.6980 in.)
-	O/S 0.5	94.402 to 94.430 mm (3.7168 to 3.7177 in.)
Piston oil clearance	STD	0.090 to 0.111 mm (0.0035 to 0.0044 in.)
-	Maximum	0.13 mm (0.0051 in.)
Piston ring groove clearance	No.1	0.030 to 0.080 mm (0.0012 to 0.0032 in.)
-	No.2	0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Piston ring end gap	No.1	0.300 to 0.400 mm (0.0118 to 0.0158 in.)
-	No.2	0.400 to 0.550 mm (0.0158 to 0.0217 in.)
-	Oil	0.130 to 0.380 mm (0.0051 to 0.0150 in.)
-	Maximum No.1	1.10 mm (0.0433 in.)
-	No.2	1.30 mm (0.0512 in.)
-	Oil	0.90 mm (0.0354 in.)
Camshaft timing tube assy		-
Journal oil diameter	STD	0.036 to 0.057 mm (0.0014 to 0.0022 in.)
-	Maximum	0.075 mm (0.0030 in.)
Connecting rod		-
Thrust clearance	STD	0.160 to 0.290 mm (0.0063 to 0.0114 in.)
-	Maximum	0.35 mm (0.0138 in.)
Connecting rod thickness		22.880 to 22.920 mm (0.9008 to 0.9024 in.)
Connecting rod oil clearance	STD	0.021 to 0.047 mm (0.0008 to 0.0019 in.)
-	Maximum	0.065 mm (0.0026 in.)
Connecting rod bearing center wall thickness		-
-	Mark 2	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
-	Mark 3	1.490 to 1.493 mm (0.0587 to 0.0588 in.)
-	Mark 4	1.493 to 1.496 mm (0.0588 to 0.0589 in.)
-	Mark 5	1.496 to 1.499 mm (0.0589 to 0.0590 in.)
-	Mark 6	1.499 to 1.502 mm (0.0590 to 0.0591 in.)
-	Mark 7	1.502 to 1.505 mm (0.0591 to 0.0593 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 to 22.014 mm (0.8663 to 0.8667 in.)
Piston pin diameter		21.997 to 22.006 mm (0.8660 to 0.8664 in.)
Bushing oil clearance	STD	0.005 to 0.011 mm (0.0002 to 0.0004 in.)
-	Maximum	0.05 mm (0.0020 in.)
Connecting rod bolt tension portion diameter	STD	7.200 to 7.300 mm (0.2835 to 0.2874 in.)
-	Maximum	7.00 mm (0.2756 in.)
Crankshaft		-
Thrust clearance	STD	0.020 to 0.220 mm (0.0008 to 0.0087 in.)
-	Maximum	0.30 mm (0.0118 in.)
Thrust washer thickness	STD	2.440 to 2.490 mm (0.0961 to 0.0980 in.)
-	U/S 0.125	2.503 to 2.553 mm (0.0985 to 0.1005 in.)
Main journal bore diameter on cylinder block		72.000 to 72.016 mm (2.8347 to 2.8353 in.)
Main journal oil clearance	No.1 and No.5 STD	0.028 to 0.046 mm (0.0011 to 0.0018 in.)
-	Others STD	0.040 to 0.058 mm (0.0016 to 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 to 67.000 mm (2.6373 to 2.6378 in.)
Main bearing center wall thickness	No.1 and No.5 Mark 3	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
-	Mark 4	2.490 to 2.493 mm (0.0980 to 0.0982 in.)
-	Mark 5	2.493 to 2.496 mm (0.0982 to 0.0983 in.)
-	Mark 6	2.496 to 2.499 mm (0.0983 to 0.0984 in.)
-	Mark 7	2.499 to 2.502 mm (0.0984 to 0.0985 in.)
-	Other Mark 1	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
-	Mark 2	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
-	Mark 3	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
-	Mark 4	2.490 to 2.493 mm (0.0980 to 0.0982 in.)
-	Mark 5	2.493 to 2.496 mm (0.0981 to 0.0983 in.)
Crank pin diameter		51.982 to 52.000 mm (2.0465 to 2.0472 in.)
Circle runout	Maximum	0.04 mm (0.0016 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.)