SERVICE PRECAUTIONS
| WARNING | When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to extremely high voltage. |
| WARNING | Read ALL service precautions before proceeding with service procedure. Vehicle is equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see AIR BAG SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM . |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION before disconnecting battery. |
The Following Service Precautions Must Be Followed
Scheme 16
- Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above shift lever position indicator on instrument cluster at center of instrument panel.
- Read all service and warning labels in engine compartment before performing any procedures.
- All high-voltage wiring harnesses contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors.
- High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components.
- If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of luggage compartment, near high-voltage battery. (Scheme 16) Ensure service plug is stored in a location in which no one may install service plug while technician is working on vehicle.
- If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves by applying air to insulated glove before touching any high-voltage wiring harness, connectors or components.
- DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit.
- If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface.
- If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
| Application | In. (mm) |
|---|
| Crankshaft |
| End Play |
| Standard | .0035-.0075 (.090-.190) |
| Wear Limit | .0118 (.300) |
| Runout | .0012 (.030) |
| Thrust Washer Thickness | .0957-.0976 (2.430-2.480) |
| Main Bearing |
| Journal Diameter (1) |
| Size Mark "0" | 1.81054-1.81062 (45.988-45.990) |
| Size Mark "1" | 1.81062-1.81071 (45.990-45.992) |
| Size Mark "2" | 1.81071-1.81078 (45.992-45.994) |
| Size Mark "3" | 1.81078-1.81086 (45.994-45.996) |
| Size Mark "4" | 1.81086-1.81094 (45.996-45.998) |
| Size Mark "5" | 1.81094-1.81102 (45.998-46.000) |
| Journal Out-Of-Round | .0008 (.020) |
| Journal Taper | .0008 (.020) |
| Oil Clearance |
| Standard | .0004-.0009 (.010-.023) |
| Wear Limit | .0028 (.070) |
| Connecting Rod Bearings |
| Journal Diameter | 1.5745-1.5748 (39.992-40.000) |
| Journal Out-Of-Round | .0008 (.020) |
| Journal Taper | .0008 (.020) |
| Oil Clearance |
| Standard | .0006-.0016 (.016-.040) |
| Wear Limit | .0024 (.060) |
| (1) Main bearing journal diameter is identified by size mark on crankshaft. see scheme 4 |
| (1) | Main bearing journal diameter is identified by size mark on crankshaft. see scheme 4 |
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CONNECTING RODS
| Application | In. (mm) |
|---|
| Bearing Center Wall Thickness (1) |
| Size Mark "1" | .0586-.0587 (1.488-1.492) |
| Size Mark "2" | .0587-.0589 (1.492-1.496) |
| Size Mark "3" | .0589-.0591 (1.496-1.500) |
| Maximum Bend | .0020 Per 3.94 (.050 Per 100.0) |
| Maximum Twist | .0020 Per 3.94 (.050 Per 100.0) |
| Cap Bolt Tension Area Minimum Diameter | .252 (6.4) |
| Side Play |
| Standard | .0063-.0142 (.160-.360) |
| Wear Limit | .0142 (.360) |
| (1) Bearing center wall thickness is identified by size mark on connecting rod cap and bearing shell. see scheme 3 |
| (1) | Bearing center wall thickness is identified by size mark on connecting rod cap and bearing shell. see scheme 3 |
ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS
| Application | In. (mm) |
|---|
| Piston |
| Diameter | 2.9506-2.9510 (74.945-74.955) |
| Oil Clearance |
| Standard | .0018-.0027 (.045-.068) |
| Wear Limit | .0031 (.080) |
| Piston Pin Diameter | .7086-.7089 (17.988-18.007) |
| Piston Pin-To-Rod Clearance | Push Fit |
| Rings |
| No. 1 |
| End Gap |
| Standard | .0087-.0126 (.220-.320) |
| Wear Limit | .0346 (.880) |
| Side Clearance | .0012-.0028 (.030-.070) |
| No. 2 |
| End Gap |
| Standard | .0126-.0185 (.320-.470) |
| Wear Limit | .0406 (1.03) |
| Side Clearance | .0012-.0028 (.030-.070) |
| No. 3 (Oil) |
| End Gap |
| Standard | .0059-.0177 (.150-.450) |
| Wear Limit | .0362 (.920) |
ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS
CYLINDER BLOCK
| Application | In. (mm) |
|---|
| Cylinder Bore Diameter |
| Standard | 2.9526-2.9533 (75.000-75.013) |
| Maximum | 2.9533 (75.013) |
| Main Bearing Bore Inside Diameter (1) |
| Size Mark "0" | 1.9685-1.9686 (50.000-50.003) |
| Size Mark "1" | 1.9686-1.9687 (50.003-50.005) |
| Size Mark "2" | 1.9687-1.9688 (50.005-50.007) |
| Size Mark "3" | 1.9688-1.9689 (50.007-50.010) |
| Size Mark "4" | 1.9689-1.9690 (50.010-50.012) |
| Size Mark "5" | 1.9690-1.96905 (50.012-50.014) |
| Size Mark "6" | 1.96905-1.9691 (50.014-50.016) |
| Cap Bolt Tension Area Minimum Diameter | .287 (7.3) |
| Maximum Deck Warpage | .002 (.05) |
| (1) Main bearing bore inside diameter is identified by size mark on cylinder block. see scheme 4 |
| (1) | Main bearing bore inside diameter is identified by size mark on cylinder block. see scheme 4 |
TIMING CHAIN
| Application | In. (mm) |
|---|
| Chain Damper & Slipper Wear Limit | .039 (1.0) |
| Chain Length (16 Links) | 4.850 (123.2) |
| Sprocket Diameter (With Chain) |
| Camshaft | 3.787 (96.2) |
| Crankshaft | 1.988 (50.5) |
VALVES & VALVE SPRINGS
| Application | Specification |
|---|
| Intake Valve |
| Face Angle (Degrees) | 44.5 Degrees |
| Minimum Margin | .028 In. (.70 mm) |
| Minimum Refinish Length | 3.494 In. (88.75 mm) |
| Stem Diameter | .1957-.1963 In. (4.970-4.985 mm) |
| Exhaust Valves |
| Face Angle (Degrees) | 44.5 Degrees |
| Minimum Margin | .028 In. (.70 mm) |
| Minimum Refinish Length | 3.441 In. (87.40 mm) |
| Stem Diameter | .1955-.1961 In. (4.965-4.980 mm) |
| Valve Springs |
| Free Length | 2.353 In. (59.77 mm) |
| Out-Of-Square | .063 In. (1.60 mm) |
| Lbs. @ In. (kg @ mm) |
| Pressure Valve Closed | 31.5-34.6 @ 1.280 (14.3-15.7 @ 32.50) |
| Pressure Valve Opened | 40.4-44.8 @ .941 (18.4-20.2 @ 23.90) |
CYLINDER HEAD
| Application | Specification |
|---|
| Maximum Warpage |
| Cylinder Block Surface | .002 In. (.05 mm) |
| Manifold Surface | .0394 In. (1.0 mm) |
| Valve Seat |
| Seat Angle | 45° |
| Seat Width | .039-.055 In. (1.00-1.40 mm) |
| Valve Guide |
| Valve Guide Head Bore I.D. |
| Standard | .3813-.3821 In. (9.685-9.706 mm) |
| Oversize | .3833-.3841 In. (9.735-9.756 mm) |
| Valve Guide I.D. | .1972-.1980 In. (5.010-5.030 mm) |
| Valve Guide Protrusion | .354-.370 In. (9.0-9.4 mm) |
| Valve Stem-To-Guide Oil Clearance |
| Standard |
| Exhaust | .0012-.0026 In. (.030-.065 mm) |
| Intake | .0010-.0024 In. (.025-.060 mm) |
| Maximum |
| Exhaust | .0039 In. (.100 mm) |
| Intake | .0031 In. (.08 mm) |
CAMSHAFT
| Application | In. (mm) |
|---|
| End Play |
| Standard | .0016-.0037 (.040-.095) |
| Wear Limit | .0043 (.110) |
| Journal Diameter |
| No. 1 Journal | 1.3563-1.3569 (34.449-34.465) |
| All Others | .9035-.9041 (22.949-22.965) |
| Journal Runout | .0012 (.030) |
| Lobe Height |
| Intake |
| Standard | 1.62637-1.66968 (42.310-42.410) |
| Wear Limit | 1.6598 (42.16) |
| Exhaust |
| Standard | 1.73409-1.73803 (44.046-44.146) |
| Wear Limit | 1.7283 (43.90) |
| Oil Clearance |
| Standard | .0016-.0037 (.040-.095) |
| Wear Limit | .0045 (.115) |
VALVE LIFTERS
| Application | In. (mm) |
|---|
| Bore Diameter | 1.2205-1.2215 (31.00-31.025) |
| Lifter Diameter | 1.2191-1.2196 (30.966-30.976) |
| Oil Clearance |
| Standard | .0009-.0023 (.024-.059) |
| Wear Limit | .004 (.10) |
