4E-FTE Engine Service Specifications.
Cylinder Head:
Warpage limit (block side) 0.05mm
Warpage limit (Manifold side) 0.05mm
Intake manifold:
Warpage limit 0.1mm
Exhaust manifold:
Warpage limit 0.2mm
Cylinder block:
Surface warpage limit 0.05mm
Bore diameters:
STD mark 1 = 74.000-74.010mm
STD mark 2 = 74.010mm-74.020mm
STD mark 3 = 74.020mm-74.030mm
Limit before rebore = 74.23mm
Piston diameter:
STD mark 1 = 73.900-73.910mm
STD mark 2 = 73.910mm-73.020mm
STD mark 3 = 73.920mm-73.930mm
Piston to oil clearance:
STD = 0.09-0.11mm
Limit = 0.13mm
Piston ring groove clearance:
Top ring = 0.04-0.08mm
2nd ring = 0.03-0.07mm
Piston ring end gap:
Top ring (STD) = 0.26-0.36mm
Top ring (Limit) = 0.95mm
2nd ring (STD) = 0.15-0.30mm
2nd ring (Limit) = 0.90mm
Oil control ring (STD) = 0.13-0.38mm
Oil control ring (Limit) = 0.98mm
Con-rods:
Thrust clearance (STD) = 0.15-0.35mm
Thrust clearance (Limit) = 0.45mm
Big-end inner diameter:
STD mark 1 = 43.000-43.007mm
STD mark 2 = 43.007-43.014mm
STD mark 3 = 43.014-43.021mm
U/S 0.25 = 43.000-43.021mm
Rod bearing centre wall thickness:
STD mark 1 = 1.487-1.491mm
STD mark 2 = 1.491-1.495mm
STD mark 3 = 1.495-1.499mm
U/S 0.25 = 1.607-1.613mm
Con-rod oil clearance:
STD = 0.016-0.048mm
Limit = 0.08mm
Maximum allowable bend in rod per 100mm = 0.03mm
Maximum allowable twist in rod per 100mm = 0.05mm
Crankshaft thrust clearance:
STD = 0.02-0.20mm
Limit = 0.30mm
Main journal oil clearance:
STD = 0.016-0.049mm
U/S 0.25 = 0.017-0.061mm
Limit = 0.08mm
Main journal diameter:
STD mark 0 = 46.995-47.000mm
STD mark 1 = 46.990-46.995mm
STD mark 2 = 46.985-46.990mm
Main bearing centre wall thickness:
STD mark 1 = 1.995-1.999mm
STD mark 2 = 1.999-2.003mm
STD mark 3 = 2.003-2.007mm
STD mark 4 = 2.007-2.011mm
STD mark 5 = 2.011-2.015mm
U/S 0.25 = 2.115-2.123mm
Crank pin diameter:
STD = 39.985-40.000mm
U/S 0.25 = 39.745-39.755mm
Limit = 0.06mm
Circle runout (Limit) = 0.06mm
Main journal taper and out-of-round (Limit) = 0.02mm
Crank pin taper and out-of-round (Limit) = 0.02mm
Torque settings:
Cylinder head bolt:
First 36ftlb
Second - turn 90 degrees in same sequence
Cylinder head to camshaft bearing cap:
9ftlb
Cylinder head to intake manifold:
14ftlb
Cylinder head to exhaust manifold:
35ftlb
Cylinder head to water outlet housing:
13ftlb
Cylinder head to Cylinder head cover:
61inlb ** note inch pounds, not foot pounds! **
Camshaft to Camshaft timing pulley:
37ftlb
Cylinder block to crankshaft bearing cap:
42ftlb
Cylinder block to rear main oil seal retainer:
65inlb ** again note inch pounds **
Cylinder block to oil filter union:
18ftlb
Crankshaft to flywheel:
65ftlb
Con-rod cap to con-rod:
29ftlb (18ftlb then +90 degrees)
Oil pump pulley to drive rotor:
27ftlb
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