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Original Toyota Repair Manuals.written by Toyota specifically for the year and vehicle(s) listed. Official Service Manuals that the dealers and shop technicians use to diagnose, service and repair your Toyota 4Runner, Avalon, Camry, Celica, Corolla, Cressida, Echo, FJ Cruiser, Highlander, Land Cruiser, Matrix, Paseo, Pickup, Previa, Prius, RAV4, Sequoia, Solara, T100, Tacoma, Tercel, Tundra, Van, Venza or Yaris vehicles. A must for anyone who insists on Genuine OEM quality parts. A Factory Repair Manual generally covers General Information, Service Information, Suspension, Driveline, Brakes, Steering, Engine Mechanical, Cooling, Starting, Ignition, Emission Controls, Engine Controls, Transmission, Transaxle, Exhaust System, Fuel System, HVAC, Instrumentation & Warning Systems, Battery & Charging System, Audio Systems, Lighting, Electrical, Body Interior and Exterior and more. A Wiring Diagrams Manual generally covers Connector Repair Procedures, Wiring Harness Overview, Overall Wiring Diagrams, Fuse and Relay Information, Power Distribution, Fuse Details, Ground Distribution, Component Location Charts, Component Location Views, Vehicle Repair Location Charts, Component Testing and more.

This is the Highly Detailed factory service repair manual for the2005 TOYOTA TACOMA, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. They are specifically written for the do-it-yourself-er as well as the experienced mechanic.2005 TOYOTA TACOMA Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure.

Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. 2005 toyota tacoma service repair manual. 1.

2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–101 EM ENGINE2TR-FE ENGINE MECHANICAL ENGINE UNIT COMPONENTS CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR CRANKSHAFT PULLEY CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION VALVE SUB-ASSEMBLY WATER PUMP ASSEMBLY 8.5 (87, 75 in.lbf) 8.0 (82, 71 in.lbf) CAMSHAFT TIMING CONTROL VALVE 9.0 (92, 80 in.lbf) 21 (214,15 ) x8 8.5 (87, 75 in.lbf) NO. 2 CYLINDER HEAD GASKET CYLINDER HEAD COVER GASKET 9.0 (92, 80 in.lbf) x11 OIL FILLER CAP ASSEMBRY x8 9.0 (92, 80 in.lbf) 9.0 (92, 80 in.lbf) 5.0 (51, 44 in.lbf) N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part 260 (2,650, 192) WATER PUMP GASKET A113614E01. EM–102 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM ENGINE REAR OIL SEAL RETAINER OIL FILTER BRACKET SUB-ASSEMBLY OIL PAN SUB- ASSEMBLY NO. 2 OIL PAN SUB-ASSEMBLY OIL STRAINER SUB-ASSEMBLY 38 (382, 28) OIL PAN DRAIN PLUG 9.0 (92, 80 in.lbf) x189.0 (92, 80 in.lbf) 26 (265, 19) 26 (265, 19) 26 (265, 19) x6 13 (133, 10) 25 (250, 18) NO. 1 TAPER SCREW PLUG 25 (255, 18) OIL FILTER BRACKET UNION 49 (500, 36) 49 (500, 36) O-RING OIL FILTER BRACKET GASKET 17 (175, 13) 43 (439, 32) OIL FILTER UNION 25 (255, 18) MP grease x14 26 (265, 19) N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part OIL PAN DRAIN PLUG GASKET OIL STRAINER GASKET OIL FILTER GASKET GASKET ENGINE REAR OIL SEAL A113615E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–103 EM CHAIN SUB- ASSEMBLY CHAIN TENSIONER SLIPPER NO. 1 CHAIN VIBRATION DAMPER TIMING CHAIN GUIDE 21 (214, 15) 21 (214, 15) 21 (214, 15) CRANKSHAFT TIMING GEAR 21 (214, 15) 10 (102, 7) TIMING CHAIN COVER NO.

1 CHAIN TENSIONER ASSEMBLY 10 (102, 7) 21 (214, 15) 21 (214, 15) 17 (170, 12) TIMING CHAIN COVER PLUG 21 (214, 15) x6 x8 46 (469, 34) Precoated part N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part O-RING O-RING WATER PUMP O-RING WATER PUMP O-RING TIMING CHAIN COVER OIL SEAL CHAIN TENSIONER GASKET A113616E01. EM–104 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM CAMSHAFT TIMING GEAR ASSEMBLY CAMSHAFT TIMING SPROCKET CAMSHAFTS NO.2 CAMSHAFT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY x4 16 (160, 11) 12 (122, 9) OIL DELIVERY PIPE 16 (160, 11) 16 (160, 11) x12 NO. 2 CAMSHAFT BEARING CAP NO. 1 CAMSHAFT BEARING CAP 78 (795, 58) x8 x8 NO. 2 CAMSHAFT BEARING CAP N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part O-RING A113617E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–105 EM BALANCESHAFT DRIVE GEAR SUB-ASSEMBLY NO.

2 CHAIN TENSIONER ASSEMBLY NO. 2 CHAIN VIBRATION DAMPER NO. 3 CHAIN VIBRATION DAMPER NO. 2 CRANKSHAFT TIMING SPROCKET CYLINDER HEAD SET BOLT CYLINDER HEAD SUB-ASSEMBLY NO.2 CHAIN SUB-ASSEMBLY 3rd: Turn 90° 2nd: Turn 90° 1st: 39 (398, 29) x10 PLATE WASHER 27 (270, 20) 25 (255, 18) 18 (185, 13) CRANKSHAFT PULLEY KEY BALANCESHAFT DRAIVE GEAR SHAFT 18 (185, 13) NO. 4 CHAIN VIBRATION DAMPER N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part CYLINDER HEAD GASKET A113618E01.

EM–106 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM CYLINDER HEAD SUB-ASSEMBLY INNER COMPRESSION SPRING INTAKE VALVE VALVE SPRING SEAT VALVE STEM CAP NO. 1 WITH HEAD STRAIGHT SCREW PLUG NO. 2 WITH HEAD STRAIGHT SCREW PLUG VALVE LASH ADJUSTER VALVE SPRING RETAINER LOCK RETAINER EXHAUST VALVE VALVE LASH ADJUSTER VALVE SPRING RETAINER LOCK RETAINER INNER COMPRESSION SPRING VALVE SPRING SEAT 44 (449, 32) SCREW PLUG OIL CONTROL VALVE FILTER 90 (918, 66) 30 (306, 22) VALVE STEM CAP N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part GASKET EXHAUST VALVE GUIDE BUSH VALVE STEM OIL SEAL VALVE STEM OIL SEAL INTAKE VALVE GUIDE BUSH GASKET GASKET A113619E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–107 EM NO.

1 BALANCESHAFT DRIVEN GEAR NO. 2 BALANCESHAFT DRIVEN GEAR CONNECTING ROD CONNECTING ROD BEARING CRANKSHAFT NO.1 BALANCESHAFT NO.2 BALANCESHAFT NO. 1 COMPRESSION RING NO. 2 COMPRESSION RINGOIL RING EXPANDER OIL RING RAIL PISTON PIN PISTON CYLINDER BLOCK SUB- ASSEMBRY CONNECTING ROD CAP WATER DRAIN COCK PLUG WATER DRAIN COCK SUB- ASSEMBRY NO. 1 BALANCESHAFT THRUST WASHER SINDING KEY 13 (130, 9) 25 (250, 18) NO. 1 BALANCESHAFT THRUST WASHER 18 (184, 13) 36 (365, 26) 18 (184, 13) 36 (365, 26) NO. 2 BALANCESHAFT THRUST WASHER CRANKSHAFT BEARING CAP LOWER CRANKSHAFT BEARING LOWER CRANKSHAFT THRUAT WASHER UPPER CRANKSHAFT BEARING 7.0 (71, 62 in.lbf) x4 NO.

1 OIL NOZZLESUB- ASSEMBRY UPPER CRANKSHAFT THRUAT WASHER Precoated part 1st: 25 (250, 18) 2nd: Turn 90 ° 1st: 25 (250, 18) 2nd: Turn 90 ° N.m (kgf.cm, ft.lbf): Specified torque Non-reusable part SNAP RING OIL RING SNAP RING A113611E01. EM–108 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM DISASSEMBLY 1.

REMOVE OIL FILLER CAP SUB-ASSEMBLY (a) Remove the oil filler cap sub-assembly. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve sub-assembly. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and camshaft position sensor. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and crankshaft position sensor. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Remove the bolt and camshaft timing oil control valve.

G037255E02 G037256E01 G037258E02 G037257E02 G037259E02. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–109 EM 6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 19 bolts, 2 nuts, head cover and 2 gaskets. REMOVE CRANKSHAFT PULLEY (a) Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.

(b) Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the bearing cap No.1, as shown in the illustration. (c) Using SST, loosen the crankshaft pulley bolt. SST 5 (5), 1 (d) Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST 3 (0, 0, 0, 1) G037266E01 13° 6° Timing Marks Timing Marks Timing Marks Groove G037261E05 SST Loosen Hold G037262E01 SST Hold Turn G037263E01. EM–110 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 8.

2 OIL PAN SUB-ASSEMBLY (a) Remove the drain plug and gasket. (b) Remove the 18 bolts and 2 nuts. (c) Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan sub-assembly No.2. SST 0 NOTICE: Be careful not to damage the contact surfaces of the oil pans. REMOVE OIL STRAINER SUB-ASSEMBLY (a) Remove the 2 bolts, 2 nuts, oil strainer and gasket. REMOVE OIL PAN SUB-ASSEMBLY (a) Remove the 16 bolts and 2 nuts.

Toyota Tacoma Repair Manual Pdf

G037265E01 G037267E01 G037268E01 G037269E02. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–111 EM (b) Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use.

(c) Remove the O-ring. REMOVE TIMING CHAIN COVER (a) Remove the 19 bolts and 2 nuts as shown in the illustration. Protective Tape Protective Tape G037270E01 G037271E01 G037272E02. EM–112 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and timing chain cover. (c) Remove the 3 O-rings. (d) Using a 10 mm socket hexagon wrench, remove the timing chain cover plug. REMOVE WATER PUMP ASSEMBLY (a) Remove the 8 bolts, water pump and gasket. Protective Tape Protective Tape G037273E03 G037274E01 G038407E01 G037275E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–113 EM 13.

REMOVE TIMING CHAIN GUIDE (a) Remove the 2 bolts, timing chain guide and O-ring. 1 CHAIN TENSIONER ASSEMBLY NOTICE:.

When the chain tensioner is removed, do not rotate the crankshaft. When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90 degrees to the right. (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole. (c) Remove the bolt, nut, chain tensioner assembly No.1 and gasket. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the bolt and tensioner slipper. G037278E04 Plunger Stopper Plate G037277E03 G037279E01 G037281E04.

EM–114 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 16. 1 CHAIN VIBRATION DAMPER (a) Remove the bolt, nut, and vibration damper. REMOVE CHAIN SUB-ASSEMBLY (a) Remove the chain. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET (a) Remove the crankshaft timing gear from the crankshaft. REMOVE CAMSHAFT BEARING CAP (a) Uniformly loosen and remove the 21 bearing cap bolts and 20 washers on the camshafts in the sequence shown in the illustration. (b) Remove the oil delivery pipe and O-ring from the bearing caps.

(c) Remove the 9 bearing caps. G037280E01 G037282E01 3 12 20 16 13 11 10 18 14 8 5 1 4 2 7 6 9 G037283E03 G037284E05 G037285E02. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–115 EM 20.

REMOVE CAMSHAFT (a) Remove the camshaft sub-assembly. REMOVE NO.2 CAMSHAFT (a) Remove the No.2 camshaft sub-assembly. 1 VALVE ROCKER ARM SUB- ASSEMBLY (a) Remove the 16 valve rocker arm sub-assembly. REMOVE CAMSHAFT TIMING SPROCKET (a) Fix the camshaft with a vise and then remove the sprocket bolt and camshaft timing sprocket. NOTICE: Be careful not to damage the camshaft. G037286E01 G037287E01 G037288E01 G037291E01.

Toyota Tacoma Repair Manual Online

EM–116 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 24. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (a) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked. NOTICE: Be careful not to damage the camshaft. (b) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: 2 advance side paths are provided in the groove of the camshaft.

Plug one of the paths with a rubber piece. (2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration. (3) Apply approximately 200 kPa (2.0 kgf.cm2, 28 psi) of air pressure to the two broken paths. CAUTION: Some oil splashing will occur.

Cover the paths with a shop rag. (4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path. OK: Gear rotates in the advance direction. HINT: This operation releases the lock pin for the most retarded position. (5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order. NOTICE: Do not release the air pressure from the advance side path first.

The gear may abruptly shift in the retard direction and break the lock pin. Retard Side Path Advance Side Path Open CloseOpen Close RubberVinyl Tape A062190E05 Retard Side Path Advance Side Path A062191E06 Retard Side Path Advance Side Path Decompress Hold Pressure A062192E06. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–117 EM (c) Check for smooth rotation. (1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly. OK: Gear rotates in the advance direction. CAUTION: Do not use an air pressure to perform the smooth operation check.

(d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear is locked at the most retarded position. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (a) Remove the fringe bolt and camshaft timing gear. NOTICE:. Be sure not to remove the other 3 bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Uniformly loosen the 10 bolts in the sequence shown in the illustration.

Remove the 10 cylinder head bolts and plate washers. NOTICE:. Be careful not to drop washers into the cylinder head.

Head warpage or cracking could result from removing bolts in an incorrect order. (b) Remove the cylinder head. REMOVE CYLINDER HEAD GASKET (a) Remove the cylinder head and gasket. 2 CHAIN VIBRATION DAMPER (a) Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.

(b) Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole. Fringe Bolt Straight Pin Do not Remove G037292E01 3 6 10 8 2 1 7 9 5 4 G037293E01 Stopper Plate Plunger G037294E04. EM–118 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (c) Remove the bolt and chain vibration damper No.2. 3 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and chain vibration damper No.3. 2 CHAIN TENSIONER ASSEMBLY (a) Remove the hexagon wrench from the tensioner assembly No.2.

(b) Remove the nut and chain tensioner assembly No.2. REMOVE NO.2 CHAIN SUB-ASSEMBLY (a) Remove the bolt, balanceshaft drive gear shaft and balanceshaft drive gear. (b) Remove the crankshaft timing sprocket No.2 and chain.

4 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and vibration damper No.4. G037295E01 G037296E01 G037297E01 G037298E01 G037299E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–119 EM 33.

REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY (a) Remove the 2 pulley set keys from the crankshaft. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter.

SST 1 (b) Using a 27 mm socket wrench, remove the oil filter union. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (a) Remove the 2 bolts and nut from the oil filter bracket. (b) Remove the 2 screw plugs and 2 gaskets from the oil filter bracket. G037300E02 SST G037302E02 G037462E01 G037304E02.

EM–120 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (c) Remove the oil filter bracket gasket and O-ring. (d) Using a hexagon wrench, remove the oil filter bracket union. 1 WITH HEAD TAPER SCREW PLUG (a) Remove the taper screw plug from the cylinder block. REMOVE ENGINE REAR OIL SEAL RETAINER (a) Remove the 6 bolts. (b) Using a screwdriver with its tip taped, pry out the oil seal retainer. HINT: Tape the screwdriver tip before use. Oil Filter Bracket Gasket O-Ring G037305E03 G037461E02 G038538E01 Protective Tape G037309E01.

2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–121 EM 38. REMOVE VALVE STEM CAP (a) Remove the valve stem caps from the cylinder head. HINT: Arrange the removed parts in the correct order. REMOVE VALVE LASH ADJUSTER ASSEMBLY (a) Remove the valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order. REMOVE INTAKE VALVE (a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks. SST 0 (0) (b) Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order. REMOVE EXHAUST VALVE (a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks. SST 0 (0) G037289E01 G037290E01 SST A097931E01 G037449E01 SST A097932E01. EM–122 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (b) Remove the retainer, compression spring, and valve. HINT: Arrange the removed parts in the correct order.

REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seals. REMOVE VALVE SPRING SEAT (a) Remove the valve spring seats from the cylinder head. REMOVE OIL CONTROL VALVE FILTER (a) Using an 8 mm hexagon wrench, remove the screw plug. (b) Remove the oil control valve filter and gasket.

1 WITH HEAD STRAIGHT SCREW PLUG (a) Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets. NOTICE: If water leaks from the w/ head straight screw plug No.1 or the plug corrodes, replace it.

2 WITH HEAD STRAIGHT SCREW PLUG (a) Using a 19 mm hexagon wrench, remove the screw plug and gasket. NOTICE: If water leaks from the w/ head straight screw plug No.2 or the plug corrodes, replace it. REMOVE CRANKSHAFT BEARING G037453E01 G037403E01 G037445E01 G037405E01 G037406E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–123 EM 48. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT:. Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.

REMOVE CONNECTING ROD BEARING HINT: Arrange the removed parts in the correct order. REMOVE CRANKSHAFT (a) Uniformly loosen the 10 bearing cap bolts, in several steps, in the sequence shown in the illustration. HINT:.

Keep the lower bearings and crankshaft bearing caps together. Arrange the thrust washers in the correct order. (b) Lift out the crankshaft.

(c) Remove the upper bearings and upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. REMOVE CRANKSHAFT BEARING HINT: Arrange the removed parts in the correct order.

REMOVE PISTON RING SET (a) Using a piston ring expander, remove the 2 compression rings. (b) Using a piston ring expander, remove the oil ring rail. (c) Remove the oil ring expander by hand. HINT: Arrange the piston rings in the correct order. Ridge Reamer G035191E05 4 8 10 6 2 3 7 9 5 1 G037353E01 G037374E01 G037354E01.

EM–124 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 53. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Remove the water drain cock sub-assembly from the cylinder block. (b) Remove the water drain cock plug from the water drain cock sub-assembly. REMOVE WITH PIN PISTON SUB-ASSEMBLY (a) Check the fitting condition between the piston and piston pin. (1) Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

(b) Disconnect the connecting rod from the piston. (1) Using a screwdriver, pry off the snap rings from the piston. (2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F). (3) Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

HINT:. The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. G037307E01 G035197E02 Service Hole G037386E01 80 to 90°C A001178E05 G036556E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–125 EM 55.

1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm hexagon wrench, remove the oil nozzles. REMOVE NO.1 BALANCESHAFT (a) Remove the bolt. (b) Remove the balanceshaft from the cylinder block. NOTICE: When removing the balanceshaft, make sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block side. 1 BALANCESHAFT DRIVEN GEAR (a) Mount the head portion of the balanceshaft in a vise. NOTICE: Be careful not to damage the balanceshaft.

(b) Remove the bolt. (c) Remove the balanceshaft driven gear No.1 (.1), sliding key (.2), balanceshaft thrust washer No.1 (.3) and balanceshaft thrust spacer (.4). REMOVE NO.2 BALANCESHAFT (a) Remove the 2 bolts. G037357E01 G037389E01 G037390E01.2.3.1.4 G037391E03 G037392E01. EM–126 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (b) Remove the balanceshaft from the cylinder block.

NOTICE: When removing the balanceshaft, make sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block side. 2 BALANCESHAFT DRIVEN GEAR (a) Mount the head portion of the balanceshaft in a vise. NOTICE: Be careful not to damage the balanceshaft. (b) Remove the bolt. (c) Remove the balanceshaft driven gear No.2 (.1) and balanceshaft thrust washer No.2 (.2). INSPECTION 1.

INSPECT CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 147 N (15 kgf, 33 Ibf) as shown in the illustration. (b) Using vernier calipers, measure the length of 16 links.

Maximum chain elongation: 147.5 mm (5.807 in.) If the elongation is greater than the maximum, replace the chain. NOTICE: Perform the same measurement by pulling at random in 3 or more places to obtain an average. INSPECT NO.2 CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 147 N (15 kgf, 33 Ibf) as shown in the illustration. (b) Using vernier calipers, measure the length of 16 links.

Maximum chain elongation: 123.6 mm (4.866 in.) If the elongation is greater than the maximum, replace the chain. NOTICE: Perform the same measurement by pulling at random in 3 or more places to obtain an average. G037393E01.1.2 G037394E04 Measuring Area 147 N 1 2 3 4 5 6 16 A097900E03 Measuring Area 147 N 1 2 3 4 5 6 16 A097900E03. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–127 EM 3. 1 CHAIN TENSIONER ASSEMBLY (a) Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. 2 CHAIN TENSIONER ASSEMBLY (a) Move the stopper plate downward to release the lock.

Push the plunger and check that it moves smoothly. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET (a) Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip. Minimum distance: 1.0 mm (0.039 in.) If the distance is less than the minimum, replace the sprocket. HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

(b) Wrap the chain around the sprocket. (c) Using vernier calipers, measure the sprocket diameter with the chain.

Minimum sprocket diameter (with chain): 113.8 mm (4.480 in.) HINT:. The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip. Minimum distance: 1.0 mm (0.039 in.) If the distance is less than the minimum, replace the timing gear. HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below. Plunger Stopper Plate A097905E05 Plunger Stopper Plate G037464E02 Worn Area A097906E01 Worn Area A097907E04.

EM–128 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (b) Wrap the chain around the timing gear. (c) Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 113.8 mm (4.480 in.) HINT:. The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and timing gear. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET (a) Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip. Minimum distance: 1.0 mm (0.039 in.) If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below. (b) Wrap the chain around the drive sprocket. (c) Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 59.4 mm (2.338 in.) HINT:. The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.

INSPECT CHAIN TENSIONER SLIPPER (a) Using vernier calipers, measure the tensioner slipper wear. Maximum wear: 2.0 mm (0.079 in.) If the wear is greater than the maximum, replace the tensioner slipper. 1 CHAIN VIBRATION DAMPER (a) Using vernier calipers, measure the vibration damper wear. Maximum wear: 2.0 mm (0.079 in.) If the wear is greater than the maximum, replace the vibration damper. Worn Area A097908E02 2.0 mm A097909E02 2.0 mm A097910E02. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–129 EM 10. INSPECT TIMING CHAIN GUIDE (a) Using vernier calipers, measure the chain guide wear.

Maximum wear: 0.5 mm (0.020 in.) If the wear is greater than the maximum, replace the timing chain guide. 2 CRANKSHAFT TIMING SPROCKET (a) Wrap the chain around the sprocket.

(b) Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 96.7 mm (3.807 in.) HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.

INSPECT BALANCESHAFT DRIVE GEAR SUB- ASSEMBLY (a) Wrap the chain around the sprocket. (b) Using vernier calipers, measure the sprocket diameter with the chain.

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Minimum sprocket diameter (with chain): 75.9 mm (2.988 in.) HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. 2 CHAIN VIBRATION DAMPER (a) Using vernier calipers, measure the vibration damper No.2 wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the vibration damper.

Wear 0.5 mm A097911E03 G038149E01 G038148E01 Wear G037311E03. EM–130 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 14. 3 CHAIN VIBRATION DAMPER (a) Using vernier calipers, measure the vibration damper No.3 wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the vibration damper. 4 CHAIN VIBRATION DAMPER (a) Using vernier calipers, measure the vibration damper No.4 wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the vibration damper. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.

Standard outside diameter: 10.76 to 10.97 mm (0.4236 to 0.4319 in.) Minimum outside diameter: 10.40 mm (0.4094 in.) HINT:. If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter. If the diameter is less than the minimum, replace the cylinder head bolt.

INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY (a) Install the 2 pulley keys to the crankshaft. Wear A068741E03 Wear A068742E03 Measuring Point: 20 mm (0.79 in.) Elongated Thread G035889E04 G037300E02. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–131 EM 18.

4 CHAIN VIBRATION DAMPER (a) Install the vibration damper No.4 with the 2 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 19. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTICE:.

Keep the lash adjuster free from dirt and foreign objects. Only use clean engine oil. (a) Place the lash adjuster into a container full of engine oil. (b) Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger. SST 0 (c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times. (d) Check the movement of the plunger and bleed the air. OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed. (e) After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.

OK: Plunger is very difficult to move. If the result is not as specified, replace the lash adjuster.

G037299E01 CORRECT INCORRECT SST Taper Part Plunger Low Pressure Chamber Checkball High pressure Chamber SST G037328E01. EM–132 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 20. INSPECT CYLINDER HEAD FOR FLATNESS (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of contacting the cylinder block and manifolds. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder head.

INSPECT CYLINDER HEAD FOR CRACKS (a) Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head. INSPECT INTAKE VALVE SEAT (a) Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve face against the valve seat. (c) Check the valve face and valve seat by using the following procedure. (1) If prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.

(2) If prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.). Cylinder Block Side Intake Manifold Side Exhaust Manifold Side G037407E01 G037408E01 Width G037409E01.

2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–133 EM 23. INSPECT EXHAUST VALVE SEAT (a) Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve face against the valve seat. (c) Check the valve face and valve seat by using to the following procedure.

(1) If prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. (2) If prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.). INSPECT CAMSHAFT (a) Check the camshaft for runout. (1) Place the camshaft on V-blocks.

(2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 42.855 to 42.955 mm (1.6872 to1.6911 in.) Minimum cam lobe height: 42.855 mm (1.6872 in.) If the cam lobe height is less than the minimum, replace the camshaft.

(c) Using a micrometer, measure the journal diameter. Standard journal diameter If the journal diameter is not as specified, check the oil clearance. Width G037410E01 G037415E01 G037416E01 G037417E01 No.1 journal 35.949 to 35.965 mm (1.4153 to 1.4159 in.) Other journal 26.959 to 26.975 mm (1.0614 to 1.0620 in.). EM–134 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 25. INSPECT NO.2 CAMSHAFT (a) Check the camshaft for runout.

(1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 42.854 to 42.954 mm (1.687 to 1.6911 in.) Minimum cam lobe height: 42.854 mm (1.6872 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Using a micrometer, measure the journal diameter.

Standard journal diameter If the journal diameter is not as specified, check the oil clearance. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts.

(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.10 to 0.24 mm (0.004 to 0.009 in.) Maximum thrust clearance: 0.26 mm (0.010 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps and camshaft journals. (b) Place the camshafts on the cylinder head.

(c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. Torque: 16 N.m (160 kgf.cm, 11 ft.lbf) NOTICE: Do not turn the camshaft.

(e) Remove the bearing caps. G037418E01 G037419E01 G037420E01 No.1 journal 35.949 to 35.965 mm (1.4153 to 1.4159 in.) Other journal 26.959 to 26.975 mm (1.0614 to 1.0620 in.) G037421E01 Plastigage G037422E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–135 EM (f) Measure the Plastigage at its widest point. Standard oil clearance Maximum oil clearance: 0.08 mm (0.003 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.

(g) Completely remove the Plastigage. INSPECT INNER COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the inner compression spring. Free length: 48.53 mm (1.9106 in.) If the free length is not as specified, replace the spring. (b) Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.5 mm (0.059 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring. INSPECT INTAKE VALVE (a) Using vernier calipers, measure the valve's overall length. Standard overall length: 106.26 mm (4.1835 in.) Minimum overall length: 105.96 mm (4.1716 in.) If the overall length is less than the minimum, replace the valve.

(b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Plastigage G037423E01 No.1 journal 0.035 to 0.072 mm (0.0014 to 0.0029 in.) Other journal 0.025 to 0.062 mm (0.00098 to 0.0024 in.) G037424E01 Deviation G037425E01 Overall Length G037426E01 G037427E01. EM–136 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (c) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.05 to 1.45 mm (0.0413 to 0.0571 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) Thickness If the margin thickness is less than the minimum, replace the valve. INSPECT EXHAUST VALVE (a) Using vernier calipers, measure the valve's overall length. Standard overall length: 106.74 mm (4.2024 in.) Minimum overall length: 106.44 mm (4.1905 in.) If the overall length is less than the minimum, replace the valve.

(b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 in.) (c) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.2 to 1.6 mm (0.0472 to 0.0630 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the valve.

INSPECT VALVE GUIDE BUSHING (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) (Intake) 0.030 to 0.065 mm (0.0012 to 0.0026 in.) (Exhaust) Margin Thickness G037428E01 Overall Length G037429E01 G037430E01 Margin Thickness G037431E01 G039582E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–137 EM Maximum oil clearance: 0.08 mm (0.0032 in.) (Intake) 0.10 mm (0.0039 in.) (Exhaust) HINT:. If the clearance is greater than the maximum, replace the intake valve and intake guide bush. If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance: 0.150 to 0.350 mm (0.0059 to 0.0138 in.) Maximum thrust clearance: 0.40 mm (0.016 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

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INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly. HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly. (b) Remove the 2 connecting rod cap bolts. (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches.

(f) Lay a strip of Plastigage on the crank pin. G037344E01 G037345E02 Plastigage G037346E03. EM–138 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (g) Check that the front mark of the connecting rod cap is facing forward. (h) Install the connecting rod cap. NOTICE: Do not turn the crankshaft. (i) Remove the 2 bolts and connecting rod cap (see steps (b) and (c) above).

(j) Measure the Plastigage at its widest point. Standard oil clearance: 0.024 to 0.049 mm (0.0009 to 0.0019 in.) Maximum oil clearance: 0.066 mm (0.0026 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings.

If necessary, replace the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2 and 3 mark on its surface. Reference Crankshaft pin diameter Standard bearing center wall thickness (k) Completely remove the Plastigage. Front Mark G037347E02 G037348E01 Plastigage 4, 5 or 6 Mark G039628E02 Mark Thickness 4 52.989 to 53.002 mm (2.0862 to 2.0867 in.) 5 52.989 to 53.002 mm (2.0862 to 2.0867 in.) 6 52.989 to 53.002 mm (2.0862 to 2.0867 in.) Mark Thickness 4 1.484 to 1.487 mm (0.0584 to 0.0585 in.) 5 1.488 to 1.490 mm (0.0586 to 0.0587 in.) 6 1.491 to 1.493 mm (0.0587 to 0.0588 in.). 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–139 EM 34.

INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 in.) 35. CLEAN WITH PIN PISTON SUB-ASSEMBLY (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. 1 OIL NOZZLE SUB-ASSEMBLY (a) Check the oil nozzles for damage or clogging.

If necessary, replace the oil nozzle. G037352E01 G035192E01 G035193E01 G035194E01. EM–140 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 37. INSPECT BALANCE SHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth.

Standard thrust clearance: 0.07 to 0.13 mm (0.0027 to 0.0051 in.) Maximum thrust clearance: 0.20 mm (0.0079 in.) If the thrust clearance is greater than the maximum, replace the balanceshaft thrust washer. If necessary, replace the balanceshaft. INSPECT CYLINDER BLOCK FOR FLATNESS (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders.

If necessary, replace the cylinder block. G037388E01 G037356E01 G035190E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–141 EM 39. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A in the thrust and axial directions. Standard diameter: 94.990 to 95.003 mm (3.7398 to 3.7403 in.) Maximum difference diameter: 0.2 mm (0.008 in.) If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block. (b) Inspect the cylinder ridge.

If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. CLEAN CYLINDER BLOCK (a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. (b) Using a soft brush and solvent, thoroughly clean the cylinder block. INSPECT PISTON DIAMETER (a) Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.

Distance: 9.3 mm (0.366 in.) Piston diameter: 94.941 to 94.971 mm (3.7378 to 3.7390 in.) (for standard) Front 70 mm (2.76 in.) Thrust Direction Axial Direction A G037358E02 Ridge Reamer G035191E05 G035189E01 Distance 9.3 mm (0.366 in.) G037359E03. EM–142 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 42. INSPECT PISTON OIL CLEARANCE (a) Measure the cylinder bore diameter in the thrust directions (see step 20).

(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 in.) If the oil clearance is greater than the standard, replace all the pistons and rebore all the cylinders. If necessary, replace the cylinder block. HINT:.

Bore all the cylinders for the O/S piston outside diameter. Replace all the piston rings with ones to match the O/S pistons. (c) If the oil clearance is greater than the standard.

(1) Prepare 4 new O/S pistons. O/S 0.50 piston diameter: 95.441 to 95.451 mm (3.7575 to 3.7579 in.) (2) Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end. Distance: 9.3 mm (0.366 in.) (3) Calculate the amount each cylinder is to be rebored as follows: Size to be rebored = P + C -H (4) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished roundness. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Ring groove clearance If the clearance is not as specified, replace the piston. P Piston diameter C Piston clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 in.) H Allowance for honing: 0.02 mm (0.0008 in.) or less G037360E01 No.1 0.020 to 0.075 mm (0.0008 to 0.0030 in.) No.2 0.020 to 0.065 mm (0.0008 to 0.0026 in.) Oil 0.020 to 0.070 mm (0.0008 to 0.0028 in.). 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–143 EM 44. INSPECT PISTON RING END GAP (a) Insert the piston ring into the cylinder bore.

(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. (c) Using a feeler gauge, measure the end gap. Standard end gap Maximum end gap If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

INSPECT PISTON PIN OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston pin hole inside diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Piston Ring 110 mm G037361E01 G037362E01 No.1 0.22 to 0.34 mm (0.0087 to 0.0134 in.) No.2 0.45 to 0.57 mm (0.0177 to 0.0224 in.) Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.) No. 1 0.90 mm (0.0354 in.) No.2 1.36 mm (0.0535 in.) Oil 0.75 mm (0.0295 in.) G037363E01. EM–144 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM (b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) (c) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) (d) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement.

Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.) Maximum oil clearance: 0.010 mm (0.0004 in.) HINT: If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. 6 mm (0.24 in.) 31 mm (1.22 in.) 6 mm (0.24 in.) G037364E01 G037365E01. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–145 EM (e) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.025 mm (0.0010 in.) (f) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set. INSPECT CONNECTING ROD (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for bend.

Maximum bend: 0.03 mm (0.0012 in.) per 100 mm (3.94 in.) If the bend is greater than the maximum, replace the connecting rod sub-assembly. (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod sub-assembly. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt.

Piston Pin Hole Inside Diameter Mark Front Mark Front Mark Connecting Rod Bushing Inside Diameter Mark G037367E01 A054727E01 A054728E01 G037366E01. EM–146 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM 48. INSPECT CRANKSHAFT (a) Inspect for circle runout. (1) Place the crankshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the crankshaft. (b) Inspect the main journals. (1) Using a micrometer, measure the diameter of each main journal. Standard journal diameter: If the diameter is not as specified, check the oil clearance (see step 30). If necessary, replace the crankshaft.

(2) Check each main journal for taper and out-of- round as shown in the illustration. Maximum taper and out-of-round: 0.005 mm (0.0002 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. (c) Inspect the crank pin.

(1) Using a micrometer, measure the diameter of each crank pin. Diameter: 52.989 to 53.002 mm (2.0862 to 2.0867 in.) If the diameter is not as specified, check the oil clearance (see step 2).

If necessary, replace the crankshaft. (2) Check each crank pin for taper and out-of- round as shown in the illustration. Maximum taper and out-of-round: 0.003 mm (0.0001 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. INSPECT CRANKSHAFT OIL CLEARANCE HINT:. Keep the lower bearings and crankshaft bearing caps together.

Arrange the thrust washers in the correct order. Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block. (a) Clean each main journal and bearing.

(b) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. (c) Place the crankshaft on the cylinder block. G037368E01 No.1 No.2 No.3 No.4 No.5 G037369E02 No.3 journal 59.981 to 59.994 mm (2.3615 to 2.3620 in.) Except No.3 journal 59.987 to 60.000 mm (2.3619 to 2.3622 in.) G037370E02. 2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–147 EM (d) Lay a strip of Plastigage across each journal. (e) Install the 5 crankshaft bearing caps in their proper locations. (f) Install the 5 crankshaft bearing caps with the 10 bolts (see step 49).

NOTICE: Do not turn the crankshaft. (g) Remove the 10 bolts and 5 crankshaft bearing caps. (h) Measure the Plastigage at its widest point. Standard oil clearance Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the crankshaft bearing. HINT:. If replacing the cylinder block, measure the bearing standard clearance.

If replacing a bearing, first check the number on the cylinder block for the bearing's respective journal. Then replace the bearing with one that has the same number. Each bearing's standard thickness is indicated by a 1, 2 or 3 mark on its surface.

Reference Cylinder block main journal bore diameter Standard bearing center wall thickness (i) Completely remove the Plastigage. Plastigage G037376E02 G037377E02 Plastigage No.1 No.2 No.4 No.5 No.3 Mark 1, 2, 3 G039585E03 Bearing Cap Standard No.3 0.030 to 0.055 mm (0.0012 to 0.0022 in.) Others 0.024 to 0.049 mm (0.0009 to 0.0019 in.) Mark Diameter 1 64.004 to 64.010 mm (2.5198 to 2.5201 in.) 2 64.011 to 64.016 mm (2.5201 to 2.5203 in.) 3 64.017 to 64.022 mm (2.5203 to 2.5206 in.) Mark Thickness 1 1.987 to 1.990 mm (0.0782 to 0.0783 in.) 2 1.991 to 1.993 mm (0.0784 to 0.0785 in.) 3 1.994 to 1.996 mm (0.0785 to 0.0786 in.). Hello Thank you very much for your patience. At the bottom of the page there is a FREE ADD TO CART button. Click on it and you will get zip file on the bottom Please click here.

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