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Service Data

ENGINE MECHANICAL SPECIFICATIONS (1ZZ-FE)

Ignition timing w/ Terminal TC and CG of DLC3 connected 8 - 12°GBTDC
W/ Terminal TC and CG of DLC3 disconnected 10 - 18°BTDC
Idle speed 650 - 750 rpm
Compression  
Compression pressure 1,300 kPa (13.3 kgf.cm2 , 189 psi)
Minimum pressure 1,000 kPa (10.2 kgf.cm2 , 145 psi)
Difference between each cylinder 100 kPa (1.0 kgf.cm2 , 15 psi)
Cylinder head set bolt Length Standard 146.8 - 148.2 mm (5.780 - 5.835 in.)
Maximum 148.5 mm (5.846 in.)
Valve clearance (Cold)  
No. 1 Cylinder TDC/Compression Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.)
  Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
No. 4 Cylinder TDC/Compression Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.)
  Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
Chain elongation Maximum 122.6 mm (4.827 in.)
Camshaft timing gear diameter (w/ chain) Minimum 97.3 mm (3.831 in.)
Crankshaft timing gear Diameter (w/ chain) Minimum 51.6 mm (2.032 in.)
Chain tensioner slipper wear Maximum 1.0 mm (0.039 in.)
Chain vibration damper wear Maximum 1.0 mm (0.039 in.)
Camshaft  
Circle runout Maximum 0.03 mm (0.0012 in.)
Cam lob height Standard Intake 44.333 - 44.433 mm (1.7454 - 1.7493 in.)
  Exhaust 43.761 - 43.861 mm (1.7229 - 1.7268 in.)
  Minimum Intake 44.18 mm (1.7394 in.)
  Exhaust 43.61 mm (1.7169 in.)
Journal diameter No. 1 34.449 - 34.465 mm (1.3563 - 1.3569 in.)
  Others 22.949 - 22.965 mm (0.9035 - 0.9041 in.)
Cylinder head warpage Cylinder block side 0.05 mm (0.0020 in.)
  Intake manifold side 0.10 mm (0.0039 in.)
  Exhaust manifold side 0.10 mm (0.0039 in.)
Camshaft thrust clearance Standard 0.040 - 0.095 mm (0.0016 - 0.0037 in.)
  Maximum 0.110 mm (0.0043 in.)
Camshaft oil clearance Standard 0.035 - 0.072 mm (0.0014 - 0.0028 in.)
  Maximum 0.10 mm (0.0039 in.)
Valve lifter diameter 30.966 - 30.976 mm (1.2191 - 1.2195 in.)
Valve lifter bore diameter 31.000 - 31.025 mm (1.2205 - 1.2215 in.)
Valve lifter oil clearance Standard 0.024 - 0.059 mm (0.0009 - 0.0023 in.)
Maximum 0.079 mm (0.0031 in.)
Inner compression spring  
Free length 43.40 mm (1.7087 in.)
Deviation 1.6 mm (0.063 in.)
Angle (reference) 2°
Installed tension at 33.6 mm (1.323 in.) 158.6 - 175.4 N (16.2 - 17.9 kgf, 35.7 - 39.5 lbf)
Maximum working tension at 24.1 mm (0.949 in.) 335.3 - 370.7 N (34.2 - 37.8 kgf, 75.4 - 83.3 lbf)
Valve  
Overall length Standard Intake 88.65 mm (3.4902 in.)
  Exhaust 88.69 mm (3.4917 in.)
  Minimum Intake 88.35 mm (3.4784 in.)
  Exhaust 88.39 mm (3.4799 in.)
Valve stem diameter Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.)
  Exhaust 5.465 - 5.480 mm (0.2152 - 0.2158 in.)
Margin thickness Standard 1.0 mm (0.039 in.)
  Minimum 0.7 mm (0.028 in.)
Valve guide bushing inside diameter 5.510 - 5.530 mm (0.2169 - 0.2177 in.)
Valve guide Bushing oil clearance Standard 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 (0.0032 in.)
  Exhaust 0.10 mm (0.0039 in.)
Valve guide bushing bore diameter STD 10.285 - 10.306 mm (0.4049 - 0.4058 in.)
  O/S 0.05 10.335 - 10.356 mm (0.4069 - 0.40// in.)
Valve guide bushing protrusion height 8.7 - 9.1 mm (0.343 - 0.358 in.)
Straight pin protrusion height (cylinder head) 5 mm (0.197 in.)
Union protrusion height A 29 mm (1.142 in.)
  R 66.5 mm (2.618 in.)
  C 24 mm (0.945 in.)
Connecting rod thrust clearance Standard 0.160 - 0.342 mm (0.063 - 0.135 in.)
  Maximum 0.342 mm (0.135 in.)
Connecting rod oil clearance Standard 0.028 - 0.060 mm (0.0011 - 0.0024 in.)
  Maximum 0.080 mm (0.0032 in.)
Connecting rod large end bore diameter 1 47.000 - 47.008 mm (1.85039 - 1.85071 in.)
  2 47.009 - 47.016 mm (1.85075 - 1.85102 in.)
  3 47.017 - 47.024 mm (1.85106 - 1.85134 in.)
Connecting rod bearing thickness 1 1.486 - 1.490 mm (0.05850 - 0.05866 in.)
  2 1.491 - 1.494 mm (0.05870 - 0.05882 in.)
  3 1.495 - 1.498 mm (0.05886 - 0.05898 in.)
Crankshaft pin outer diameter 43.992 - 44.000 mm (1.73197 - 1.73228 in.)
Crankshaft thrust clearance Standard 0.04 - 0.24 mm (0.0016 - 0.0095 in.)
  Maximum 0.30 mm (0.0118 in.)
Cylinder block warpage Maximum 0.05 mm (0.0020 in.)
Cylinder bore diameter 79.000 - 79.013 mm (3.1102 - 3.1108 in.)
Piston diameter at 25.6 mm (1.008 in.) from piston head 78.872 - 78.972 mm (3.1052 - 3.1091 in.)
Piston oil clearance Standard 0.065 - 0.088 mm (0.0026 - 0.0035 in.)
  Maximum 0.088 mm (0.0035 in.)
Piston pin bore diameter A 20.006 - 20.009 mm (0.78764 - 0.78776 in.)
  B 20.010 - 20.012 mm (0.78780 - 0.78787 in.)
  C 20.013 - 20.015 mm (0.78791 - 0.78799 in.)
Piston pin outer diameter A 20.004 - 20.007 mm (0.78756 - 0.78768 in.)
  B 20.008 - 20.010 mm (0.78772 - 0.78780 in.)
  C 20.011 - 20.013 mm (0.78783 - 0.78791 in.)
Connecting rod small end bore diameter A 20.012 - 20.015 mm (0.78787 - 0.78799 in.)
  B 20.016 20.018 mm (0.78803 0.78811 in.)
  C 20.019 - 20.021 mm (0.78815 - 0.78823 in.)
Piston pin oil clearance  
Piston pin x Piston Standard 0.002 - 0.011 mm (0.0001 - 0.0004 in.)
  Maximum 0.011 mm (0.0004 in.)
Piston pin x Connecting rod Standard -0.001 - 0.017 mm (-0.00004 - 0.0007 in.)
  Maximum 0.017 mm (0.0007 in.)
Ring groove clearance No. 1 0.020 - 0.070 mm (0.0008 - 0.0028 in.)
  No. 2 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
  Oil 0.03 - 0.11 mm (0.0012 - 0.0043 in.)
Piston ring end gap Standard No. 1 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
  No. 2 0.35 0.50 mm (0.0138 0.0197 in.)
  Oil 0.15 - 0.40 (0.0059 - 0.158 in.)
  Maximum No. 1 1.05 mm (0.0413 in.)
  No. 2 1.20 mm (0.0472 in.)
Connecting rod  
Out-of alignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Twist Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod bolt diameter Standard 6.6 6.7 mm (0.260 0.264 in.)
  Maximum 6.4 mm (0.252 in.)
Crankshaft  
Circle runout Maximum 0.03 mm (0.0012 in.)
Main journal diameter 47.988 - 48.000 mm (1.8893 - 1.8898 in.)
Taper and out-of-round Maximum 0.020 mm (0.0008 in.)
Crank pin diameter 43.992 - 44.000 mm (1.7320 - 1.7323 in.)
Taper and out-of-round Maximum 0.020 mm (0.0008 in.)
Crankshaft bearing cap set bolt diameter Standard 7.3 - 7.5 mm (0.287 - 0.295 in.)
  Minimum 7.3 mm (0.287 in.)
Crankshaft oil clearance Standard 0.015 - 0.032 mm (0.0006 - 0.0013 in.)
  Minimum 0.05 mm (0.0020 in.)
Cylinder block journal bore diameter 0 52.000 - 52.002 mm (2.04724 - 2.04732 in.)
  1 52.003 - 52.004 mm (2.04736 - 2.04740 in.)
  2 52.005 - 52.006 mm (2.04744 - 2.04748 in.)
  3 52.007 - 52.009 mm (2.04752 - 2.04760 in.)
  4 52.010 - 52.011 mm (2.04764 - 2.04768 in.)
  5 52.012 - 52.013 mm (2.04772 - 2.04776 in.)
  6 52.014 - 52.015 mm (2.04788 - 2.04783 in.)
Crankshaft journal diameter 0 47.999 - 48.000 mm (1.88972 - 1.88976 in.)
  1 47.997 - 47.998 mm (1.88965 - 1.88969 in.)
  2 47.995 - 47.996 mm (1.88957 - 1.88961 in.)
  3 47.993 - 47.994 mm (1.88949 - 1.88953 in.)
  4 47.991 - 47.992 mm (1.88941 - 1.88945 in.)
  5 47.988 - 47.990 mm (1.88929 - 1.88922 in.)
Standard bearing center wall thickness 1 1.994 - 1.997 mm (0.07850 - 0.07862 in.)
  2 1.998 - 2.000 mm (0.07866 - 0.07874 in.)
  3 2.001 - 2.003 mm (0.07878 - 0.07886 in.)
  4 2.004 - 2.006 mm (0.07890 - 0.07898 in.)
Straight pin (Cylinder block) A 5 mm (0.200 in.)
  B 7.5 mm (0.295 in.)
  C 12 mm (0.472 in.)
  D 8 mm (0.315 in.)
Ring pin (Cylinder block) A 6 mm (0.236 in.)
  B 7 mm (0.276 in.)
  C 10 mm (0.394 in.)
ENGINE MECHANICAL SPECIFICATIONS (2ZZ-GE)

Ignition timing w/ Terminal TC and CG of DLC3 connected 8 - 12°BTDC
  W/ Terminal TC and CG of DLC3 disconnected 4 - 12°BTDC (M/T)
  10 - 18°BTDC (A/T)
Idle speed 750 - 850 rpm (M/T)
  700 - 800 rpm (A/T)
Compression  
Compression pressure 1,400 kPa (14.3kgf/cm2 203 psi)
Minimum pressure 1,000 kPa (10.3 kgf/cm2 145 psi)
Difference between each cylinder 110 kPa (1.1kgf/cm2 16 psi)
Cylinder head set bolt  
Length Standard 146.0 - 148.2 mm (5.780 - 5.835 in.)
  Maximum 148.5 mm (5.846 in.)
Valve clearance (cold) Intake 0.08 - 0.18 mm (0.0031 - 0.0071 in.)
  Exhaust 0.22 - 0.32 mm (0.0087 - 0.0126 in.)
Chain length at 16 links Maximum 122.6 mm (4.827 in.)
Camshaft timing sprocket diameter (w / chain) Minimum 97.3mm (3.831 in.)
Crankshaft timing sprocket diameter (w / chain) Minimum 51.6mm (2.031in.)
Chain tensioner slipper wear Maximum 1.0 mm (0.039 in.)
Chain tensioner vibration damper wear Maximum 1.0 mm (0.039 in.)
Camshaft circle runout Maximum 0.03 mm (0.0012 in.)
Camshaft lobe height Standard  
  Intake No. 1 40.607 - 40.707 mm (1.5987 - 1.6026 in.)
  Intake No. 2 38.769 - 38.869 mm (1.5236 - 1.5303 in.)
  Exhaust No. 1 40.019 - 40.119 mm (1.5756 - 1.5795 in.)
  Exhaust No. 2 38.863 - 38.963 mm (1.5300 - 1.5340 in.)
  Minimum
  Intake No. 1 40.45 mm (1.5925 in.)
  Intake No. 2 38.61 mm (1.5201 in.)
  Exhaust No. 1 39.86 mm (1.5693 in.)
  Exhaust No. 2 38.71 mm (1.5240 in.)
Camshaft journal diameter No. 1 34.449 - 34.465 mm (1.3563 - 1.3569 in.)
  Others 27.949 - 27.965 mm (1.1004 - 1.1010 in.)
Cylinder head warpage Maximum  
  Cylinder block side 0.2 mm (0.0080 in.)
  Intake manifold side 0.2 mm (0.0080 in.)
  Exhaust manifold side 0.3 mm (0.0120 in.)
Busing oil clearance inside diameter 5.500 5.518 mm (0.2165 0.2172 in.)
Valve stem diameter Intake 5.460 - 5.475 mm (0.2145 - 0.2156 in.)
  Exhaust 5.445 - 5.470 mm (0.2144 - 0.2154 in.)
Valve stem oil clearance Standard  
  Intake 0.025 - 0.058 mm (0.0010 - 0.0023 in.)
  Exhaust 0.030 - 0.063 mm (0.0012 - 0.0025 in.)
  Maximum
  Intake 0.10 mm (0.0039 in.)
  Exhaust 0.10 mm (0.0039 in.)
Valve guide bush diameter Use STD 10.448 - 10.506 mm (0.4129 - 0.4136 in.)
  Use O/S 10.538 - 10.556 mm (0.4149 - 0.4156 in.)
Valve spring free length Intake 46.4 mm (1.827 in.)
  Exhaust 46.5 mm (1.831 in.)
Valve spring deviation Maximum 1.6 mm (0.063 in.)
Valve spring angle (reference) Maximum 2
Valve overall length Standard Intake 111.3 mm (4.382 in.)
  Exhaust 111.7 mm (4.392 in.)
  Minimum Intake 110.9 mm (4.366 in.)
  Exhaust 111.3 mm (4.382 in.)
Valve head margin thickness Standard 1.0 mm (0.039 in.)
  Minimum 0.7 mm (0.028 in.)
Valve rocker shaft diameter 15.965 - 15.985 mm (0.6285 - 0.6293 in.)
Camshaft thrust clearance Standard 0.10 - 0.24 mm (0.0039 - 0.0095 in.)
  Maximum 0.15 mm (0.0059 in.)
Camshaft oil clearance Standard 0.025 - 0.062 mm (0.001 - 0.0024 in.)
  Maximum 0.062 mm (0.0024 in.)
Water hose union protrusion Standard A 29 mm (1.14 in.)
  B 69.8 mm (2.748 in.)
  C 24 mm (0.95 in.)
Valve guide bush protrusion height 15.3 - 15.7 mm (0.602 - 0.618 in.)
Connecting rod thrust clearance Standard 0.160 - 0.342 mm (0.0063 - 0.0135 in.)
  Maximum 0.342 mm (0.0135 in.)
Connecting rod oil clearance Standard 0.028 - 0.052 mm (0.0011 - 0.0020 in.)
  Maximum 0.080 mm (0.0031 in.)
Connecting rod bearing center wall thickness  
  1 1.482 1.486 mm (0.0583 0.0585 in.)
  2 1.486 - 1.490 mm (0.0585 - 0.0587 in.)
  3 1.490 - 1.494 mm (0.0587 - 0.0588 in.)
Connecting rod large end bore diameter  
  1 48.000 - 48.008 mm (1.8898 - 1.8901 in.)
  2 48.008 - 48.016 mm (1.8901 - 1.8904 in.)
  3 48.016 - 48.024 mm (1.8904 - 1.8907 in.)
Crankshaft pin outer diameter 44.992 - 45.000 mm (1.7713 - 1.7717 in.)
Crankshaft thrust clearance Standard 0.04 - 0.24 mm (0.0016 - 0.0094 in.)
  Maximum 0.24 mm (0.0094 in.)
Crankshaft Thrust washer thickness 2.430 - 2.480 mm (0.0957 - 0.0976 in.)
Cylinder block surface warpage Maximum 0.05 mm (0.0020 in.)
Cylinder bore diameter Standard 82.000 - 82.013 mm (3.2283 - 3.2289 in.)
  Maximum 82.013 mm (3.2289 in.)
Piston diameter (at 12 mm (0.472 in.) from the piston head) 81.975 - 81.933 mm (3.2274 - 3.2281 in.)
Connecting rod out-of alignment Maximum per/100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Connecting rod twist Maximum per/100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Piston oil clearance Standard 0.007 - 0.038 mm (0.0003 - 0.0015 in.)
  Maximum 0.10 mm (0.0039 in.)
Piston ring groove clearance No. 1 0.020 - 0.070 mm (0.0009 - 0.0028 in.)
  No. 2 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
Piston ring end gap Standard  
  No. 1 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
  No. 2 0.35 - 0.50 mm (0.0138 - 0.0197 in.)
  Maximum  
  No. 1 1.05 mm (0.041 in.)
  No. 2 1.20 mm (0.047 in.)
Piston pin diameter 20.004 - 20.016 mm (0.7876 - 0.7880 in.)
Piston bushing inside diameter 20.013 - 20.025 mm (0.7879 - 0.7884 in.)
Connecting rod bushing inside diameter 20.011 - 20.023 mm (0.7878 - 0.7883 in.)
Piston x Piston pin oil clearance 0.005 - 0.013 mm (0.0002 - 0.0005 in.)
Piston x Connecting rod oil clearance 0.005 - 0.009 mm (0.0002 - 0.0004 in.)
Connecting rod bolt diameter Standard 6.6 - 6.7 mm (0.260 - 0.264 in.)
  Maximum 6.7 mm (0.263 in.)
Crankshaft circle runout Maximum 0.03 mm (0.0012 in.)
Crankshaft main journal diameter 47.988 - 48.000 mm (1.8893 - 1.8898 in.)
  Maximum taper and out-of-round 0.02 mm (0.0008 in.)
Crank pin diameter 44.992 - 45.000 mm (1.7713 - 1.7717 in.)
  Maximum taper and out-of-round 0.02 mm (0.0008 in.)
Crankshaft bearing cap set bolt diameter Standard 7.3 - 7.5 mm (0.287 - 0.295 in.)
  Minimum 7.2 mm (0.287 in.)
Crankshaft main journal oil clearance Standard 0.016 - 0.032 mm (0.0006 - 0.0013 in.)
  Maximum 0.08 mm (0.0031 in.)
Cylinder block main journal bore diameter 0 52.000 - 52.003 mm (2.0472 - 2.0473 in.)
  1 52.003 - 52.005 mm (2.0473 - 2.0474 in.)
  2 52.005 - 52.007 mm (2.0474 - 2.0475 in.)
  3 52.007 - 52.010 mm (2.0475 - 2.0476 in.)
  4 52.010 - 52.012 mm (2.0476 - 2.0477 in.)
  5 52.012 - 52.014 mm (2.0477 - 2.0478 in.)
  6 52.014 - 52.016 mm (2.0478 - 2.0479 in.)
Crankshaft main journal diameter 0 47.998 - 48.000 mm (1.8897 - 1.8898 in.)
  1 47.996 - 47.998 mm (1.8896 - 1.8897 in.)
  2 47.994 - 47.996 mm (1.8895 - 1.8896 in.)
  3 47.992 - 47.994 mm (1.8894 - 1.8895 in.)
  4 47.990 - 47.992 mm (1.8893 - 1.8894 in.)
  5 47.988 - 47.990 mm (1.8892 - 1.8893 in.)
Standard bearing center wall thickness 1 1.989 - 1.992 mm (0.0783 - 0.0784 in.)
  2 1.992 - 1.995 mm (0.0784 - 0.0785 in.)
  3 1.995 - 1.998 mm (0.0785 - 0.0787 in.)
  4 1.998 - 2.001 mm (0.0787 - 0.0788 in.)
  5 2.001 - 2.004 mm (0.0788 - 0.0789 in.)
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