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Service Data

2AZ-FE ENGINE MECHANICAL - SERVICE DATA

Engine Ignition timing Standard When using Techstream BTDC 5 to 15° at idle
When not using Techstream BTDC 8 to 12° at idle (Connect terminals 13 (TC) and 4 (CG))
BTDC 5 to 15° at idle (Remove terminals 13 (TC) and 4 (CG))
Engine idling speed Standard 600 to 700 rpm
Compression Standard 1300 kPa (13.3 kgf/cm2 , 189 psi)
Minimum 1000 kPa (10.0 kgf/cm2 , 145 psi)
Difference between each cylinder 100 kPa (1.0 kgf/cm2 , 15 psi)
Camshaft Valve clearance Standard Intake 0.19 to 0.29 mm (0.00748 to 0.0114 in.)
Exhaust 0.38 to 0.48 mm (0.0150 to 0.189 in.)
Thrust clearance Standard Intake 0.040 to 0.095 mm (0.00157 to 0.00374 in.)
Exhaust 0.090 to 0.145 mm (0.00354 to 0.00570 in.)
Maximum Intake 0.110 mm (0.00433 in.)
Exhaust 0.150 mm (0.00591 in.)
Oil clearance Standard Camshaft No. 1 journal bearing mark 1 0.007 to 0.038 mm (0.000276 to 0.00150 in.)
Camshaft No. 1 journal bearing mark 2 0.008 to 0.038 mm (0.000315 to 0.00150 in.)
Camshaft No. 1 journal bearing mark 3 0.008 to 0.038 mm (0.000315 to 0.00150 in.)
Camshaft other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
No. 2 camshaft No. 1 journal 0.040 to 0.072 mm (0.00157 to 0.00283 in.)
No. 2 camshaft No. 1 journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum Intake 0.070 mm (0.00276 in.)
Exhaust 0.100 mm (0.00394 in.)
Circle runout Maximum 0.03 mm (0.00118 in.)
Cam lobe height Standard Intake 47.306 to 47.406 mm (1.8654 to 1.8664 in.)
Exhaust 46.063 to 46.163 mm (1.8135 to 1.8174 in.)
Minimum Intake 47.196 mm (1.8581 in.)
Exhaust 45.953 mm (1.8092 in.)
Journal diameter Standard No. 1: 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other: 22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Cylinder head Flatness Standard Cylinder block side 0.08 mm (0.00315 in.)
Intake manifold side 0.08 mm (0.00315 in.)
Exhaust manifold side 0.08 mm (0.00315 in.)
Lifter bore diameter Standard 31.009 to 31.025 mm (1.2208 to 1.2215 in.)
Cylinder head set bolt Length Standard 141.3 to 142.7 mm (5.563 to 5.618 in.)
Maximum 144.2 mm (5.677 in.)
Inner compression spring Length Standard 47.43 mm (1.867 in.)
Deviation Maximum 1.6 mm (0.0630 in.)
Intake valve Overall length Standard 101.71 mm (4.0043 in.)
Minimum 101.21 mm (3.9846 in.)
Valve stem diameter Standard 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Margin thickness Standard 1.05 to 1.45 mm (0.0413 to 0.0571 in.)
Minimum 0.50 mm (0.0197 in.)
Exhaust valve Overall length Standard 101.15 mm (3.9823 in.)
Minimum 100.70 mm (3.9646 in.)
Valve stem diameter Standard 5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Margin thickness Standard 1.20 to 1.60 mm (0.0472 to 0.0630 in.)
Minimum 0.50 mm (0.0197 in.)
Intake valve guide bush Inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Maximum 0.090 mm (0.00354 in.)
Exhaust valve guide bush Inside diameter Standard 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Maximum 0.095 mm (0.00374 in.)
Valve lifter Diameter Standard 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Oil clearance Standard 0.033 to 0.059 mm (0.00130 to 0.00232 in.)
Maximum 0.079 mm (0.00311 in.)
Connecting rod Thrust clearance Standard 0.160 to 0.362 mm (0.00630 to 0.0143 in.)
Maximum 0.362 mm (0.0143 in.)
Oil clearance Standard 0.024 to 0.048 mm (0.000945 to 0.00189 in.)
Maximum 0.063 mm (0.00248 in.)
Cylinder block War page Maximum 0.05 mm (0.00197 in.)
Cylinder bore diameter Standard 88.500 to 88.513 mm (3.4843 to 3.4847 in.)
Maximum 88.613 mm (3.4887 in.)
Piston Diameter Standard 88.469 to 88.479 mm (3.4830 to 3.4834 in.)
Oil clearance Standard 0.021 to 0.044 mm (0.000827 to 0.00173 in.)
Maximum 0.10 mm (0.00394 in.)
Ring groove clearance Standard 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.)
Piston ring End gap Standard No. 1 0.24 to 0.31 mm (0.00945 to 0.0122 in.)
No. 2 0.33 to 0.43 mm (0.0130 to 0.0169 in.)
Oil 0.10 to 0.30 mm (0.00394 to 0.0118 in.)
Maximum No. 1 0.31 mm (0.0122 in.)
No. 2 0.43 mm (0.0169 in.)
Oil 0.30 mm (0.0118 in.)
Piston pin Oil clearance (Piston pin x Piston pin bore) Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum 0.010 mm (0.000394 in.)
Oil clearance (Piston pin x Connecting rod small end bore) Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum 0.011 mm (0.000433 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.)
Connecting rod Misalignment Maximum 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
Twist Maximum 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
Crankshaft Circle runout Maximum 0.03 mm (0.00118 in.)
Main journal diameter Standard 54.988 to 55.000 mm (2.1649 to 2.1654 in.)
Main journal for taper and distortion Maximum 0.003 mm (0.000118 in.)
Crank pin diameter Standard 47.990 to 48.000 mm (1.8894 to 1.8898 in.)
Crank pin for taper and distortion Maximum 0.003 mm (0.000118 in.)
Thrust clearance Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Maximum 0.30 mm (0.0118 in.)
Oil clearance Standard 0.017 to 0.040 mm (0.000669 to 0.00157 in.)
Maximum 0.060 mm (0.00236 in.)
Crankshaft bearing cap set bolt Diameter Standard 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum 7.5 mm (0.295 in.)
Balance shaft Thrust clearance Standard 0.05 to 0.09 mm (0.00197 to 0.00354 in.)
Maximum 0.09 mm (0.00354 in.)
Oil clearance Standard 0.022 to 0.049 mm (0.000866 to 0.00193 in.)
Maximum 0.049 mm (0.00193 in.)
Balance shaft housing bolt Length Standard 58.3 to 59.7 mm (2.295 to 2.350 in.)
Maximum 60.3 mm (2.374 in.)
Chain sub-assembly Elongation Maximum 114.5 mm (4.508 in.)
No. 2 chain sub-assembly Elongation Maximum 102.2 mm (4.024 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 97.3 mm (3.831 in.)
Camshaft timing gear or sprocket Diameter (with chain) Minimum 97.3 mm (3.831 in.)
Crankshaft timing gear or sprocket Diameter (with chain) Minimum 51.6 mm (2.031 in.)
Chain tensioner slipper Maximum Wear 1.0 mm (0.0394 in.)
No. 1 chain vibration damper Maximum Wear 1.0 mm (0.0394 in.)
Chain tensioner plate Maximum Wear 0.5 mm (0.0197 in.)
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