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Lotus Service Notes Section TDP
CYLINDER HEAD 2ZZ-GE 1ZZ-FE
Material Aluminium alloy -
Head face flatness tolerance 0.05 mm -
Reface limit No machining -
VALVES & SPRINGS
Valve seat angle in head 45° -
Valve face angle 44.5° -
Cold valve clearance (between cam & follower) - inlet 0.10 - 0.16 mm 0.15 - 0.25 mm
- exhaust 0.24 - 0.30 mm 0.25 - 0.35 mm
Valve guide standout 15.3 - 15.7 mm 8.7 - 9.1 mm
Valve spring free length - inlet 46.4 mm 45.9 mm
- exhaust 46.5 mm 45.9 mm
CAMSHAFTS
End float - new 0.04 - 0.14 mm 0.04 - 0.10 mm
- service limit 0.15 mm 0.11 mm
PISTONS
Diameter - @ 90° to pin, 12 mm from bottom edge 81.975 - 81.993 mm
- @ 90° to pin, 25 mm from top edge 78.925 - 78.935 mm
Ring gap, 110 mm from block top face - std. - no.1 0.25 - 0.35 mm -
- no.2 0.35 - 0.50 mm -
- oil rail 0.15 - 0.40 mm -
- max. - no.1 1.1 mm -
- no.2 1.2 mm -
- oil rail 1.1 mm -
Ring groove clearance 0.030 - 0.070 mm -
CONNECTING ROD
Small end bush inside diameter 20.011 - 20.023 mm 20.012 - 20.021 mm
Big end side clearance 0.16 - 0.34 mm -
CRANKSHAFT
Crankshaft endfloat - new 0.04 - 0.24 mm -
- service limit 0.30 mm -
Main journal diameter 47.988 - 48.000 mm -
Crankpin diameter 44.992 - 45.000 mm 43.992 - 44.000 mm
Max. taper & out of round, journals & crankpins 0.02 mm -
OIL PUMP
Oil pressure - idle, running temperature 39 kPa (6 psi) min. 29 kPa (4 psi) min.
- 3,000 rpm, running temperature 300 - 540 kPa -
(45 - 80 psi)
Outer rotor to housing clearance - new 0.13 - 0.18 mm -
- service limit 0.33 mm -
Inner rotor tip clearance - new 0.06 - 0.18 mm -
- service limit 0.33 mm -
Rotor end float - new 0.03 - 0.08 mm -
- service limit 0.16 mm -
COOLANT THERMOSTAT
Valve opening temperature 80 - 84°C -
Valve lift at 90°C 10 mm -
Header tank pressure cap 108 kPa -
Cap opening pressure 93 - 123 kPa -
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