Service Data
2ZZ-GE ENGINE MECHANICAL SERVICE DATA
| Ignition timing | w/ Terminal TC and CG of DLC3 connected | 8 to 12° BTDC |
| w/ Terminal TC and CG of DLC3 disconnected | 4 to 12° BTDC | |
| Idle speed | 750 to 850 rpm | |
| Compression pressure | 1,400 kPa (14.3 kgf/cm2 , 203 psi) | |
| Minimum pressure | 1,000 kPa (10.3 kgf/cm2 , 145 psi) | |
| Difference between each cylinder | 110 kPa (1.1 kgf/cm2 , 16 psi) | |
| Valve clearance at cold | Intake | 0.08 to 0.18 mm (0.0031 to 0.0071 in.) |
| Exhaust | 0.22 to 0.32 mm (0.0087 to 0.0126 in.) | |
| Chain elongation | Maximum | 115.3 mm (4.539 in.) |
| Camshaft timing gear diameter (w/ chain) | Minimum | 96.8 mm (3.811 in.) |
| Crankshaft timing gear diameter (w/ chain) | Minimum | 51.0 mm (2.008 in.) |
| Chain tensioner slipper wear | Maximum | 1.0 mm (0.039 in.) |
| Chain vibration damper wear | Maximum | 1.0 mm (0.039 in.) |
| Cylinder head set bolt length | Standard | 146.8 to 148.2 mm (5.780 to 5.835 in.) |
| Maximum | 148.5 mm (5.846 in.) | |
| Valve rocker shaft diameter | 15.965 to 15.985 mm (0.6285 to 0.6293 in.) | |
| Camshaft | ||
| Circle runout | Maximum | 0.03 mm (0.0012 in.) |
| Cam lobe height | Standard | No. 1 40.716 to 40.816 mm (1.6030 to 1.6069 in.) |
| Standard No. 2 | 38.769 to 38.869 mm (1.5236 to 1.5303 in.) | |
| Minimum No. 1 | 40.45 mm (1.5925 in.) | |
| Minimum No. 2 | 38.61 mm (1.5201 in.) | |
| Journal diameter | No. 1 | 34.449 to 34.465 mm (1.3563 to 1.3569 in.) |
| Other | 27.949 to 27.965 mm (1.1004 to 1.1010 in.) | |
| No. 2 Camshaft | ||
| Circle runout | Maximum | 0.03 mm (0.0012 in.) |
| Cam lobe height | Standard No. 1 | 40.019 to 40.119 mm (1.5755 to 1.5795 in.) |
| Standard No. 2 | 38.863 to 38.963 mm (1.5300 to 1.5340 in.) | |
| Minimum No. 1 | 39.86 mm (1.5693 in.) | |
| Minimum No. 2 | 38.71 mm (1.5240 in.) | |
| Journal diameter | No. 1 | 34.449 to 34.465 mm (1.3563 to 1.3569 in.) |
| Other | 27.949 to 27.965 mm (1.1004 to 1.1010 in.) | |
| Cylinder head warpage | Cylinder block side | 0.20 mm (0.0080 in.) |
| Intake manifold side | 0.20 mm (0.0080 in.) | |
| Exhaust manifold side | 0.30 mm (0.0120 in.) | |
| Valve guide bush inside diameter | 5.500 to 5.518 mm (0.2165 to 0.2172 in.) | |
| Valve stem diameter | Intake | 5.460 to 5.475 mm (0.2145 to 0.2156 in.) |
| Exhaust | 5.455 to 5.470 mm (0.2144 to 0.2154 in.) | |
| Valve guide bush oil clearance | Standard Intake | 0.025 to 0.058 mm (0.0010 to 0.0023 in.) |
| Standard Exhaust | 0.030 to 0.063 mm (0.0012 to 0.0025 in.) | |
| Maximum | 0.10 mm (0.0039 in.) | |
| Valve guide bush bore diameter | STD | 10.448 to 10.506 mm (0.4129 to 0.4136 in.) |
| O/S 0.05 | 10.538 to 10.556 mm (0.4149 to 0.4156 in.) | |
| Inner compression spring | ||
| Free length | Intake | 46.4 mm (1.827 in.) |
| Exhaust | 46.5 mm (1.831 in.) | |
| Deviation | Maximum | 1.6 mm (0.063 in.) |
| Angle (reference) | Maximum | 2° |
| Intake valve | ||
| Overall length | Standard | 111.3 mm (4.382 in.) |
| Minimum | 110.9 mm (4.366 in.) | |
| Margin thickness | Standard | 1.0 mm (0.039 in.) |
| Minimum | 0.7 mm (0.028 in.) | |
| Exhaust valve | ||
| Overall length | Standard | 111.7 mm (4.392 in.) |
| Minimum | 111.3 mm (4.382 in.) | |
| Margin thickness | Standard | 1.0 mm (0.039 in.) |
| Minimum | 0.7 mm (0.028 in.) | |
| Camshaft thrust clearance | Standard | 0.04 to 0.14 mm (0.0016 to 0.0055 in.) |
| Maximum | 0.15 mm (0.0059 in.) | |
| Camshaft oil clearance | Standard | 0.025 to 0.062 mm (0.0001 to 0.0024 in.) |
| Maximum | 0.062 mm (0.0024 in.) | |
| Ring pin protrusion height | 6.4 mm (0.252 in.) | |
| Union protrusion height | 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 to 15.7 mm (0.602 to 0.618 in.) | |
| Connecting rod thrust clearance | Standard | 0.160 to 0.342 mm (0.0063 to 0.0135 in.) |
| Maximum | 0.342 mm (0.0135 in.) | |
| Connecting rod oil clearance | Standard | 0.028 to 0.052 mm (0.0011 to 0.0020 in.) |
| Maximum | 0.080 mm (0.0031 in.) | |
| Connecting rod large end bore diameter | 1 | 48.000 to 48.008 mm (1.8898 to 1.8901 in.) |
| 2 | 48.009 to 48.016 mm (1.8901 to 1.8904 in.) | |
| 3 | 48.017 to 48.024 mm (1.8904 to 1.8907 in.) | |
| Connecting rod bearing thickness | 1 | 1.482 to 1.486 mm (0.0583 to 0.0585 in.) |
| 2 | 1.487 to 1.490 mm (0.0585 to 0.0587 in.) | |
| 3 | 1.491 to 1.494 mm (0.0587 to 0.0588 in.) | |
| Crankshaft pin outer diameter | 44.992 to 45.000 mm (1.7713 to 1.7717 in.) | |
| Crankshaft thrust clearance | Standard | 0.04 to 0.24 mm (0.0016 to 0.0094 in.) |
| Maximum | 0.24 mm (0.0094 in.) | |
| Cylinder block warpage | Maximum | 0.05 mm (0.0020 in.) |
| Cylinder bore diameter | Standard | 82.000 to 82.013 mm (3.2283 to 3.2289 in.) |
| Piston diameter | at 12 mm (0.472 in.) from piston skirt | 81.975 to 81.933 mm (3.2274 to 3.2281 in.) |
| Piston oil clearance | Standard | 0.007 to 0.038 mm (0.0003 to 0.0015 in.) |
| Maximum | 0.10 mm (0.0039 in.) | |
| Connecting rod small end bore diameter | 20.011 to 20.023 mm (0.7878 to 0.7883 in.) | |
| Piston pin bore diameter | 20.013 to 20.025 mm (0.7879 to 0.7884 in.) | |
| Piston pin outer diameter | 20.004 to 20.016 mm (0.7876 to 0.7880 in.) | |
| Piston pin oil clearance | ||
| Piston x Piston pin | 0.005 to 0.013 mm (0.0002 to 0.0005 in.) | |
| Piston pin x Connecting rod | 0.005 to 0.009 mm (0.0002 to 0.0004 in.) | |
| Piston ring groove clearance | No. 1 | 0.02 to 0.07 mm (0.0009 to 0.0028 in.) |
| No. 2 | 0.03 to 0.07 mm (0.0012 to 0.0028 in.) | |
| Piston ring end gap | Standard No. 1 | 0.25 to 0.35 mm (0.0098 to 0.0138 in.) |
| Standard No. 2 | 0.40 to 0.80 mm (0.0276 to 0.0315 in.) | |
| Standard Oil | 0.10 to 0.40 mm (0.0039 to 0.0157 in.) | |
| Maximum No. 1 | 1.05 mm (0.0413 in.) | |
| Maximum No. 2 | 1.20 mm (0.0472 in.) | |
| Maximum Oil | 1.05 mm (0.0413 in.) | |
| Connecting rod | ||
| Misalignment | Maximum | 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) |
| Twist | Maximum | 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) |
| Connecting rod bolt diameter | Standard | 8.7 to 8.8 mm (0.3425 to 0.3465 in.) |
| Maximum | 6.7 mm (0.263 in.) | |
| Crankshaft | ||
| Circle runout | Maximum | 0.03 mm (0.0012 in.) |
| Main journal diameter | 47.988 to 48.000 mm (1.8893 to 1.8898 in.) | |
| Taper and out-of-round | Maximum | 0.02 mm (0.0008 in.) |
| Crank pin diameter | 44.992 to 45.000 mm (1.7713 to 1.7717 in.) | |
| Taper and out-of-round | Maximum | 0.02 mm (0.0008 in.) |
| Crankshaft bearing cap set bolt diameter | Standard | 7.3 to 7.5 mm (0.287 to 0.295 in.) |
| Minimum | 7.3 mm (0.287 in.) | |
| Crankshaft oil clearance | Standard | 0.016 to 0.032 mm (0.0006 to 0.0013 in.) |
| Minimum | 0.08 mm (0.0031 in.) | |
| Cylinder block main journal bore diameter | 0 | 52.000 to 52.002 mm (2.0472 to 2.0473 in.) |
| 1 | 52.003 to 52.004 mm (2.0473 to 2.0474 in.) | |
| 2 | 52.005 to 52.006 mm (2.0474 to 2.0475 in.) | |
| 3 | 52.007 to 52.009 mm (2.0475 to 2.0476 in.) | |
| 4 | 52.010 to 52.011 mm (2.0476 to 2.0477 in.) | |
| 5 | 52.012 to 52.013 mm (2.0477 to 2.0478 in.) | |
| 6 | 52.014 to 52.016 mm (2.0478 to 2.0479 in.) | |
| Crankshaft main journal diameter | 0 | 47.999 to 48.000 mm (1.8897 to 1.8898 in.) |
| 1 | 47.997 to 47.998 mm (1.8896 to 1.8897 in.) | |
| 2 | 47.995 to 47.996 mm (1.8896 to 1.8896 in.) | |
| 3 | 47.993 to 47.994 mm (1.8895 to 1.8895 in.) | |
| 4 | 47.991 to 47.992 mm (1.8894 to 1.8894 in.) | |
| 5 | 47.988 to 47.990 mm (1.8892 to 1.8893 in.) | |
| Standard bearing center wall thickness | 1 | 1.989 to 1.992 mm (0.0783 to 0.0784 in.) |
| 2 | 1.993 to 1.995 mm (0.0785 to 0.0785 in.) | |
| 3 | 1.996 to 1.998 mm (0.0786 to 0.0787 in.) | |
| 4 | 1.999 to 2.001 mm (0.0787 to 0.0788 in.) | |
| 5 | 2.002 to 2.004 mm (0.0788 to 0.0789 in.) | |
| Ring pin (cylinder block) | A | 7 mm (0.276 in.) |
| B | 6 mm (0.236 in.) | |
| C | 10 mm (0.394 in.) | |
| Straight pin (cylinder block) | A | 5 mm (0.197 in.) |
| B | 7.5 mm (0.295 in.) | |
| C | 9 mm (0.354 in.) | |
| D | 8 mm (0.315 in.) | |