039

SERVICE SPECIFICATIONS ENGINE MECHANICAL

ENGINE MECHANICAL
030P002

SERVICE DATA
Ignition timing w/ Terminal TC and CG of DLC3 connected 8 to 12
BTDC
w/ Terminal TC and CG of DLC3 disconnected 10 to 18
BTDC
Idle speed 650 to 750 rpm
Compression pressure 1,300 kPa (13.3 kgfcm2, 189 psi)
Minimum pressure 1,000 kPa (10.2 kgfcm2, 145 psi)
Difference between each cylinder 100 kPa (1.0 kgfcm2, 15 psi)
Valve clearance at cold Intake 0.15 to 0.25 mm (0.0059 to 0.0098 in.)
Exhaust 0.25 to 0.35 mm (0.0098 to 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 (2.031 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.)
Camshaft
Circle runout Maximum 0.03 mm (0.0012 in.)
Cam lobe height Standard Intake 44.333 to 44.433 mm (1.7454 to 1.7493 in.)
Exhaust 43.761 to 43.861 mm (1.7229 to 1.7268 in.)
Minimum Intake 44.18 mm (1.7394 in.)
Exhaust 43.61 mm (1.7169 in.)
Journal diameter No. 1 34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Others 22.949 to 22.965 mm (0.9035 to 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 to 0.095 mm (0.0016 to 0.0037 in.)
Maximum 0.110 mm (0.0043 in.)
Camshaft oil clearance Standard 0.035 to 0.072 mm (0.0014 to 0.0028 in.)
Maximum 0.10 mm (0.0039 in.)
Valve lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Valve lifter bore diameter 31.000 to 31.025 mm (1.2205 to 1.2215 in.)
Valve lifter oil clearance Standard 0.024 to 0.059 mm (0.0009 to 0.0023 in.)
Maximum 0.079 mm (0.0031 in.)
Inner compression spring
Free length 43.40 mm (1.7087 in.)
Deviation Maximum 1.6 mm (0.063 in.)
Angle (reference) Maximum 2

Installed tension at 33.6 mm (1.323 in.) 158.6 to 175.4 N (16.2 to 17.9 kgf, 35.7 to 39.5 lbf)
Maximum working tension at 24.1 mm (0.949 in.) 335.3 to 370.7 N (34.2 to 37.8 kgf, 75.4 to 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 to 5.485 mm (0.2154 to 0.2159 in.)
Exhaust 5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Margin thickness Standard 1.0 mm (0.039 in.)
Minimum 0.7 mm (0.028 in.)
Valve guide bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Valve guide bush oil clearance Standard 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 (0.0032 in.)
Exhaust 0.10 mm (0.0039 in.)

2004 COROLLA (RM1037U)

Author: Date: 113

Valve guide bush bore diameter STD 10.285 to 10.306 mm (0.4049 to 0.4058 in.)
O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Valve guide bush protrusion height 8.7 to 9.1 mm (0.343 to 0.358 in.)
Straight pin protrusion height (cylinder head) 5 mm (0.197 in.)
Union protrusion height A 29 mm (1.142 in.)
(See page 14134) B 66.5 mm (2.618 in.)
C 24 mm (0.945 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 0.060 mm (0.0011 to 0.0024 in.)
Maximum 0.080 mm (0.0031 in.)
Connecting rod large end bore diameter 1 47.000 to 47.008 mm (1.8504 to 1.8507 in.)
2 47.009 to 47.016 mm (1.8507 to 1.8510 in.)
3 47.017 to 47.024 mm (1.8511 to 1.8513 in.)
Connecting rod bearing thickness 1 1.486 to 1.490 mm (0.0585 to 0.0587 in.)
2 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
3 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
Crankshaft pin outer diameter 43.992 to 44.000 mm (1.7320 to 1.7323 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 79.000 to 79.013 mm (3.1102 to 3.1107 in.)
Difference limit 0.10 mm (0.0039 in.)
Piston diameter at 25.6 mm (1.008 in.) from piston head 78.872 to 78.972 mm (3.1052 to 3.1091 in.)
Piston oil clearance Standard 0.065 to 0.088 mm (0.0026 to 0.0035 in.)
Maximum 0.088 mm (0.0035 in.)
Piston pin bore diameter A 20.006 to 20.009 mm (0.7876 to 0.7878 in.)
B 20.010 to 20.012 mm (0.7878 to 0.7879 in.)
C 20.013 to 20.015 mm (0.7879 to 0.7880 in.)
Piston pin outer diameter A 20.004 to 20.007 mm (0.7876 to 0.7877 in.)
B 20.008 to 20.010 mm (0.7877 to 0.7878 in.)
C 20.011 to 20.013 mm (0.7878 to 0.7879 in.)
Connecting rod small end bore diameter A 20.012 to 20.015 mm (0.7879 to 0.7880 in.)
B 20.016 to 20.018 mm (0.7880 to 0.7881 in.)
C 20.019 to 20.021 mm (0.7881 to 0.7882 in.)
Piston pin oil clearance
Piston pin x Piston Standard 0.002 to 0.011 mm (0.0001 to 0.0004 in.)
Maximum 0.011 mm (0.0004 in.)
Piston pin x Connecting rod Standard 0.001 to 0.017 mm (0.00004 to 0.0007 in.)
Maximum 0.017 mm (0.0007 in.)
Ring groove clearance No. 1 0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2 0.03 to 0.07 mm (0.0012 to 0.0028 in.)
Oil 0.03 to 0.11 mm (0.0012 to 0.0043 in.)
Piston ring end gap Standard No. 1 0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No. 2 0.35 to 0.50 mm (0.0138 to 0.0197 in.)
Oil 0.15 to 0.40 mm (0.0059 to 0.157 in.)
Maximum No. 1 1.05 mm (0.0413 in.)
No. 2 1.20 mm (0.0472 in.)
Connecting rod
Outofalignment 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 to 6.7 mm (0.260 to 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 to 48.000 mm (1.8893 to 1.8898 in.)
Taper and outofround Maximum 0.02 mm (0.0008 in.)
Crank pin diameter 43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Taper and outofround Maximum 0.02 mm (0.0008 in.)
2004 COROLLA (RM1037U)

Author: Date: 114

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 0.015 to 0.032 mm (0.0006 to 0.0013 in.)
Minimum 0.05 mm (0.0020 in.)
Cylinder block journal bore diameter 0 52.000 to 52.002 mm (2.0472 to 2.0473 in.)
1 52.003 to 52.004 mm (2.0474 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 52.015 mm (2.0478 to 2.0478 in.)
Crankshaft 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 (1.8893 to 1.8894 in.)
Standard bearing center wall thickness 1 1.994 to 1.997 mm (0.0785 to 0.0786 in.)
2 1.998 to 2.000 mm (0.0787 to 0.0787 in.)
3 2.001 to 2.003 mm (0.0788 to 0.0789 in.)
4 2.004 to 2.006 mm (0.0789 to 0.0790 in.)
Straight pin (cylinder block) A 5 mm (0.197 in.)
(See page 14147) 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.)
(See page 14147) B 7 mm (0.276 in.)
C 10 mm (0.394 in.)

2004 COROLLA (RM1037U)

Author: Date: 115