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Service Data

2UR-GSE ENGINE MECHANICAL - SERVICE DATA

Ignition timing Terminal TC and CG of DLC3 connected 8 to 12° BTDC at idle
Terminals TC and CG of DLC3 disconnected 8 to 18°BTDC at idle
Idle speed 700 to 800 rpm
Compression Standard 1400kPa (14.0kgf/cm2 , 203 psi) or more
Minimum 980kPa (10.0kgf/cm2 , 142 psi)
Difference 100 kPa (10 kgf/cm2 , 14.5 psi) or less
Valve clearance at cold Intake 0.12 to 0.18 mm (0.00472 to 0.00709 in)
Exhaust 0.22 to 0.28 mm (0.00866 to 0.0110 in)
Exhaust manifold Warpage Maximum 0.5 mm (0.0197 in)
Timing chain No. 1 chain Chain elongation Maximum 136.9 mm (5.39 in)
No. 2 chain 137.6 mm (5.42 in)
Crankshaft timing gear Sprocket diameter (w/ chain) Minimum 61.4 mm (2.42 in)
Crankshaft timing sprocket LH 61.4 mm (2.42 in)
No. 2 chain tensioner Depth Maximum 0.9 mm (0.0354 in)
No. 3 chain tensioner 0.9 mm (0.0354 in)
Chain tensioner slipper 1.0 mm (0.0394 in)
No. 1 chain vibration damper 1.0 mm (0.0394 in)
Camshaft timing gear Keyway width Standard 5.9 to 6.2 mm (0.232 to 0.244 in)
Maximum 6.7 mm (0.264 in)
Camshaft Circle runout Maximum 0.04 mm (0.00157 in)
Cam lobe height Intake Standard 44.953 to 45.103 mm (1.7698 to 1.7757 in)
Minimum 44.903 mm (1.7678 in)
Exhaust Standard 44.576 to 44.726 mm (1.7549 to 1.7609 in)
Minimum 44.526 mm (1.7530 in)
Journal diameter No. 1 journal Standard 29 956 to 29 970 mm (1.1794 to 1.1799 in)
Other journal 25 959 to 25 975 mm (1.0220 to 1.0226 in)
Oil clearance No. 1 journal Standard 0.030 to 0.069 mm (0.00118 to 0.00272 in)
Maximum 0.09 mm (0.00354 in)
Other journal Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in)
Maximum 0.09 mm (0.00354 in)
Cylinder head Warpage Cylinder head lower side Standard 0.05 mm (0.00197 in)
Intake side 0.08 mm (0.00315 in)
Exhaust side 0.05 mm (0.00197 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 1.25 mm (0.0492 in)
Minimum 0.50 mm (0,0197 in)
Overall length Standard 105 85 mm (4 17 in)
Minimum 105.35 mm (4 15 in)
Width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 in)
Exhaust Valve stem diameter Standard 5.465 to 5.480 mm (0.215 to 0.216 in)
Margin thickness Standard 1.4 mm (0.0551 in)
Minimum 0.50 mm (0.0197 in.)
Overall length Standard 110.40 mm (4 35 in)
Minimum 109 90 mm (4 33 in)
Width Standard 1.3 to 1.7 mm (0.0512 to 0.0669 in)
Compression spring (Intake side) Free length Standard 47 86 mm (1.88 in)
Deviation Maximum 1.0 mm (0.0394 in)
Angle (reference) Maximum 2°
Compression spring (Exhaust side) Free length Standard 47 24 mm (1.86 in)
Deviation Maximum 1.0 mm (0.0394 in)
Angle (reference) Maximum 2°
Valve guide bush Bush inside diameter Standard 5.51 to 5.53 mm (0.217 to 0.218 in)
Valve guide bush oil clearance Intake Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in)
Maximum 0.08 mm (0.00315 in)
Exhaust Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in)
Maximum 0.10 mm (0.00394 in)
Camshaft thrust clearance Standard 0.08 to 0,14 mm (0.00315 to 0.00551 in)
Maximum 0.15 mm (0.00591 in)
Cylinder bore diameter Standard 10.285 to 10.306 mm (0.405 to 0.406 in)
Valve guide bush bore diameter STD 10.285 to 10.306 mm (0.405 to 0.406 in)
O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in)
Protrusion height Standard 14 3 to 14.7 mm (0.563 to 0.579 in)
Cylinder block Warpage Maximum 0.05 mm (0.00197 in)
Cylinder bore Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in)
Maximum 94 200 mm (3.7087 in)
Connecting rod Thrust clearance Standard 0.15 to 0.55 mm (0.00591 to 0.0217 in)
Maximum 0.70 mm (0.0276 in)
Oil clearance Standard 0.037 to 0.062 mm (0.00146 to 0.00244 in)
Maximum 0.080 mm (0.00315 in)
Connecting rod Standard sized bearing Center wall thickness Mark 2 1.483 to 1.486 mm (0.0584 to 0.0585 in)
Mark 3 1.486 to 1.489 mm (0.0585 to 0.0586 in)
Mark 4 1.489 to 1.492 mm (0.0586 to 0.0587 in)
Mark 5 1.492 to 1.495 mm (0.0587 to 0.0589 in)
Mark 6 1.495 to 1.498 mm (0.0589 to 0.0590 in)
Mark 7 1.498 to 1.501 mm (0.0590 to 0.0591 in)
Big end Inside diameter Mark 1 56.000 to 56.006 mm (2.2047 to 2.2050 in)
Mark 2 56.007 to 56.012 mm (2.2050 to 2.2052 in)
Mark 3 56.013 to 56.018 mm (2.2052 to 2.2054 in)
Mark 4 56.019 to 56.024 mm (2.2055 to 2.2057 in)
Crankshaft Crankshaft pin Diameter Mark 1 52.995 to 53.000 mm (2.0864 to 2.0866 in)
Mark 2 52.989 to 52.994 mm (2.0862 to 2.0864 in)
Mark 3 52.982 to 52.998 mm (2.0859 to 2.0861 in)
Thrust clearance Standard 0.020 to 0.220 mm (0.000787 to 0.00866 in)
Maximum 0.30 mm (0.0118 in)
Thrust washer thickness Standard 2.44 to 2.49 mm (0.0961 to 0.0980 in)
Piston Diameter Standard 93.980 to 93.990 mm (3.7000 to 3.7004 in)
Minimum 93.830 mm (3.6941 in)
Oil clearance Standard 0.010 to 0.032 mm (0.000394 to 0.00126 in)
Maximum 0.370 mm (0.0146 in)
Piston ring Groove clearance No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in)
No. 2 0.020 to 0.060 mm (0.000787 to 0.00236 in)
Oil 0.020 to 0.070 mm (0.000787 to 0.00276 in)
End gap Standard No. 1 0.23 to 0.33 mm (0.00906 to 0.0130 in)
No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in)
Oil 0.10 to 0.40 mm (0.00394 to 0.0157 in)
Maximum No. 1 0.40 mm (0.0157 in)
No. 2 0.50 mm (0.0197 in)
Oil 0.45 mm (0.0177 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 0.86629 in)
Mark C 22.005 to 22.007 mm (0.86634 to 0.86642 in)
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 (0.86629 to 0.86638 in)
Oil clearance Standard -0.002 to 0.004 mm (-0.0000787 to 0.000158 in)
Maximum 0.015 mm (0.000591 in)
Connecting rod bush Inside diameter Mark A 22.005 to 22.008 mm (0.86634 to 0.86646 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)
Oil clearance Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in)
Maximum 0.03 mm (0.00118 in)
Connecting rod Bend Maximum 0.05 mm (0.00197 in) per 100 mm (3.94 in)
Twist Maximum 0.15 mm (0.00591 in) per 100 mm (3.94 in)
Connecting rod bolt Diameter Standard 8.5 to 8.6 mm (0.335 to 0.339 in)
Minimum 8 3 mm (0.327 in)
Crankshaft Circle runout Maximum 0.01 mm (0.000394 in)
Main journal Diameter Standard 66 988 to 67.000 mm (2.63731 to 2.63779 in)
Crank pin Diameter Standard 52.982 to 53.000 mm (2.08590 to 2.08661 in)
Oil clearance No. 1 and No. 5 journal Standard 0.017 to 0.030 mm (0.000669 to 0.00118 in)
Maximum 0.050 mm (0.00197 in)
Other journal Standard 0.024 to 0.037 mm (0.000945 to 0.00146 in)
Maximum 0.060 mm (0.00236 in)
Main journal diameter Mark 00 66 999 to 67.000 mm (2.63775 to 2.63779 in)
Mark 01 66 998 to 66 999 mm (2.63771 to 2.63775 in)
Mark 02 66 997 to 66 998 mm (2.63767 to 2.63771 in)
Mark 03 66 996 to 66 997 mm (2.63763 to 2.63767 in)
Mark 04 66 995 to 66 996 mm (2.63759 to 2.63763 in)
Mark 05 66 994 to 66 995 mm (2.63755 to 2.63759 in)
Mark 06 66 993 to 66 994 mm (2.63751 to 2.63755 in)
Mark 07 66 992 to 66 993 mm (2.63748 to 2.63751 in)
Mark 08 66 991 to 66 992 mm (2.63744 to 2.63748 in)
Mark 09 66 990 to 66 991 mm (2.63740 to 2.63744 in)
Mark 10 66 989 to 66 990 mm (2.63736 to 2.63740 in)
Mark 11 66 988 to 66 989 mm (2.63732 to 2.63736 in)
Bearing center wall thickness No. 1 and No. 5 journal Upper bearing 00 to 02 4 2.501 to 2.504 (0.0985 to 0.0986 in)
03 to 05 5 2.504 to 2.507 (0.0986 to 0.0987 in)
06 to 08 5 2.504 to 2.507 (0.0986 to 0.0987 in)
09 to 11 6 2.507 to 2.510 (0.0987 to 0.0988 in)
12 to 14 6 2.507 to 2.510 (0.0987 to 0.0988 in)
15 to 17 7 2.510 to 2.513 (0.0988 to 0.0989 in)
18 to 20 7 2.510 to 2.513 (0.0988 to 0.0989 in)
21 to 23 8 2.513 to 2.516 (0.0989 to 0.0991 in)
24 to 26 8 2.513 to 2.516(0.0989 to 0.0991 in)
27 to 28 9 2.516 to 2.519 (0.0991 to 0.0992 in)
Lower bearing 00 to 02 5 2.488 to 2.491 (0.0980 to 0.0981 in)
03 to 05 5 2.488 to 2.491 (0.0980 to 0.0981 in)
06 to 08 6 2.491 to 2.494 (0.0981 to 0.0982 in)
09 to 11 6 2.491 to 2.494 (0.0981 to 0.0982 in)
12 to 14 7 2.494 to 2.497 (0.0982 to 0.0983 in)
15 to 17 7 2.494 to 2.497 (0.0982 to 0.0983 in)
18 to 20 8 2.497 to 2.500 (0.0983 to 0.0984 in)
21 to 23 8 2.497 to 2.500 (0.0983 to 0.0984 in)
24 to 26 9 2.500 to 2.503 (0.0984 to 0.0985 in)
27 to 28 9 2.500 to 2.503 (0.0984 to 0.0985 in)
Bearing center wall thickness other journal Upper bearing 00 to 02 3 2.482 to 2.485 (0.0977 to 0.0978 in)
03 to 05 4 2.485 to 2.488 (0.0978 to 0.0980 in)
06 to 08 4 2.485 to 2.488 (0.0978 to 0.0980 in)
09 to 11 5 2.488 to 2.491 (0.0980 to 0.0981 in)
12 to 14 5 2.488 to 2.491 (0.0980 to 0.0981 in)
15 to 17 6 2.491 to 2.494 (0.0981 to 0.0982 in)
18 to 20 6 2.491 to 2.494 (0.0981 to 0.0982 in)
21 to 23 7 2.494 to 2.497 (0.0982 to 0.0983 in)
24 to 26 7 2.494 to 2.497 (0.0982 to 0.0983 in)
27 to 28 8 2.497 to 2.500 (0.0983 to 0.0984 in)
Lower bearing 00 to 02 4 2.501 to 2.504 (0.0985 to 0.0986 in)
03 to 05 4 2.501 to 2.504 (0.0985 to 0.0986 in)
06 to 08 5 2.504 to 2.507 (0.0986 to 0.0987 in)
09 to 11 5 2.504 to 2.507 (0.0986 to 0.0987 in)
12 to 14 6 2.507 to 2.510 (0.0987 to 0.0988 in)
15 to 17 6 2.507 to 2.510 (0.0987 to 0.0988 in)
18 to 20 7 2.510 to 2.513 (0.0988 to 0.0989 in)
21 to 23 7 2.510 to 2.513 (0.0988 to 0.0989 in)
24 to 26 8 2.513 to 2.516 (0.0989 to 0.0991 in)
27 to 28 8 2.513 to 2.516 (0.0989 to 0.0991 in)
Crankshaft bearing cap set bolt Diameter Bolt A Standard 10.8 to 11.0 mm (0.425 to 0.433 in)
Minimum 10.7 mm (0.421 in)
Bolt B Standard 9 8 to 10.0 mm (0.386 to 0.394 in)
Minimum 9 7 mm (0.382 in)
Crankshaft bearing Bearing cap's edge and the lower bearing's edge Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in)
Connecting rod bearing connecting rod's and bearing cap's edges Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in)
Cylinder head set bolt Outside diameter Standard 10.85 to 11.00 mm (0.427 to 0.433 in)
Minimum 10.6 mm (0.417 in)
No. 1 ventilation connector Acceptable angle -5° to 5°
Tap-in depth 0.2 to 3 2 mm (0.00787 to 0.126 in)
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