Technician Handbook

151 Engine Service and Repair

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Shop Safety Be sure to watch out for the safety of coworkers when working together. Keep
the work area clean and neat.

When working with the engine running, make sure to provide ventilation for
exhaust fumes in the workshop.

If working on high temperature, high pressure, rotating, moving, or vibrating

parts, wear appropriate safety equipment and take extra care not to injure
yourself or others.

When lifting the vehicle, be sure to support the specified location with a safety
stand and use appropriate safety equipment.

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Engine Lift Always follow the safety procedures outlined by your dealership and/or the lift
manufacturer. Use extreme caution when lifting, lowering and moving heavy
loads. Always use proper engine mounting equipment and make sure they are
securely connected. Refer to the Repair Manual for proper service procedures.

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Parts Washers Parts washers will use either a water-based solvent or a solvent-based solution.
Be sure you know which type is used because some solvents are harmful to
aluminum parts.
•  For water based solvent, be sure to blow parts dry and lightly oil them.
•  For a solvent-based washer, wash with water, then dry and lightly oil.
•  Use a wire wheel to clean bolts, if necessary, to remove rust corrosion, loc-
tite, sealant, etc.

Cylinder Head Cleaning Clean the entire cylinder head prior to disassembly if it has excessive residue.
•  After the parts are removed, wash the cylinder head again separately.
•  Cleaning valves – Use a wire wheel to remove carbon buildup.
•  Immersion cleaners may be most effective at cleaning a cylinder head’s oil
galleys and blind passages.

Cylinder Block Cleaning •  Remove plugs from oil galleries and coolant passages.
•  Remove all gasket material and/or seal packing.
•  Do not hot tank aluminum parts as they will be damaged.
•  Spray with an appropriate water and solvent mixture following supplier’s
precautions.
•  Have a variety of wire brushes available to clean with. Use a rifle brush to
clean oil galleries.
•  Spray iron/ferrous components thoroughly with a rust inhibitor and dry
immediately.
•  Dry thoroughly with compressed air and paper towels.

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Engine Sealing Automotive engines have dozens of mated surfaces and moving parts. For the
engine to function properly these surfaces, orifices, and moving parts need to
be sealed off from one another depending on their function or design.

Toyota uses various methods for engine sealing depending on application or

function. Solid gaskets are typically used to seal between non-moving parts.
These gaskets can be made of various material such as paper, cork, plastic
polymer and rubber. For moving parts such as oil or water pumps a dynamic
seal is used. These seals are often made of rubber or neoprene.

NOTE It is important to always clean mating surfaces before installing gaskets or

seals. Some dynamic seals may require a small amount of lubrication upon
installation. See the Repair Manual for proper installation procedure.

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Seal Installation To ensure seals are not damaged during installation, special SSTs are
available. It is important to use these SSTs to ensure the seal is properly
aligned, at the correct depth, and not damaged during installation.

NOTE Care must also be taken when removing seals so as not to scratch or otherwise
damage the contact surfaces. If using a screwdriver to pry out a seal, tape the
screwdriver tip to reduce the risk of scratching the contact surface.

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FIPG Form-in-place gasket (FIPG) is used to seal a multitude of surfaces on modern

Toyota engines. There are many different types of FIPG on the market for
various applications. It is important to use the proper sealer for each
application.

For sealing against oil leaks, use Toyota Formed-In-Place Gasket - Oil Pan
(part no. 00295-00103). Also known as Toyota Seal Packaging 102, this product
replaces Toyota Genuine Seal Packing Black, (or Three Bond 1207B, or
equivalent) that is specified in the Repair Manuals.

For sealing against water leaks, use Toyota Genuine Seal Packing 1282B (part
no. 08826-00100). The Repair Manual specifies Three Bond 1282B or
equivalent as alternatives.

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Seal Packing Application During application, it is crucial that certain protocols are followed to ensure the
mating surfaces seal. The surface must be thoroughly cleaned of used FIPG as
well as oil and any other residues. Caution must be taken while cleaning the
surface. To prevent damage to the mating surface do not use abrasive pads or
pneumatic tools. Consult the Repair Manual for where to apply the sealer and
the correct amount to use.

NOTE It is important to apply sealer in the correct diameter and only in the prescribed
areas. This minimizes seepage and most importantly prevents FIPG from
entering and blocking oil feed holes or coolant passages.

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Dye Penetrant Although cracks in the cylinder head or cylinder block are not common, un
undiscovered crack can result in a misdiagnosis and a failed repair attempt. It’s
important to check for cracks, especially around the combustion chamber,
coolant passages and oil passages.

One way to check for cracks is to use dye penetrant. This multistep application
uses various dyes and chemicals to highlight trouble areas that could be
otherwise hard to see. If you are not confident using this product it’s advisable
to send the components to a professional machine shop to have the component
checked using alternative methods.

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Plastigage Plastigage provides an effective method for measuring clearances between

fitted surfaces such as bearings and journals. Plastigage is ideally suited for
measurements on components such as crankshaft journals because clearances
can be measured without removing the component.

Plastigage is a thin plastic thread that is placed between two surfaces where
clearance is to be measured. When the components are assembled and
properly torqued, the plastic thread is compressed and flattened. The width of
the flattened plastic is then compared to a measurement chart to determine the
clearance between the two mating surfaces. Plastigage comes in different
diameters suitable for different clearance ranges.

NOTE It is important to clean the bearing and journal surfaces beforehand, and to
remove the Plastigage residue with a clean cloth afterward.

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Thread Cleaning Bolt threads and threads in bolt holes must be free of FIPG and oily dirt in order
to achieve proper torque during reassembly.

A finishing tap should be used to “chase” (clean) bolt holes. Do not confuse a
finishing tap with a starter tap. A starter tap is tapered at the end to gradually
begin the thread cutting in a new hole. In a blind hole that is already threaded,
the tapered end will not clean the threads at the bottom of the hole.

NOTE A finishing tap may not be included in every tap and die set.

Use an appropriate size die to clean bolt threads. Inspect threads for damage
and replace as necessary.

Start all bolts by hand. If the bolt gets too tight to turn by hand, stop. Remove
the bolt and inspect it, and chase the bolt hole.

Be careful that there is no coolant or oil in a blind bolt hole. When the bolt
reaches the uncompressible liquid, it cannot be tightened any further.

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Illustration by Joaquim Alves Gaspar

Vernier Caliper The caliper, in this case a Vernier caliper, is a versatile measuring tool that can
be used for making inside, outside, and even depth measurements. The Vernier
caliper is different from traditional calipers because of the addition of the Vernier
scale. The Vernier scale allows for an additional decimal point of accuracy.

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Reading a Vernier Caliper To read the Vernier scale, find a hash mark on the Vernier scale that aligns
perfectly with any hash mark on the main scale. Then read the value from the
Vernier scale associated with that hash mark.

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NOTES:

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Micrometer The micrometer is used exclusively for outside diameter measurements.

Micrometers come in ranges of measurement diameters. It is important to
select a micrometer with the correct measurement range for the component
being measured.

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Reading a Micrometer The micrometer is fairly easy to read. First, note the largest value visible on the
millimeter scale. In the example above, the reading is 16 mm.

Next note if there is a half-millimeter mark displayed. In the example above,

there is a half-millimeter mark showing, so we add 0.5 mm to the measurement.

Finally, we take the reading on the thimble that aligns most closely with the
millimeter scale, in this case 0.04mm.

Adding all the readings together we obtain a measurement of 16.54 mm.

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NOTES:

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Micrometer with As with the calipers, micrometers often come equipped with a Vernier scale.
Vernier Scale The Vernier scale allows us to obtain an extra decimal place of accuracy on our
measurements.

When there is a Vernier scale, look for the hashmark on the Vernier scale that
most closely aligns with a hashmark on the 1/100th millimeter scale.

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Digital Micrometer Some technicians prefer the speed and simplicity of a digital micrometer.

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Inside Diameter Inside diameter gauges come in a variety of different configurations and
Gauges designs to fit a variety of applications. Typically, the inside diameter gauge is
inserted and expanded to the dimension to be measured, and then locked in
place. It is then removed and measured with a micrometer to obtain the actual
measurement.

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Dial Indicator Dial indicators use a spring loaded pin to translate up and down movement into
an incremental measurement. Dial indicators are extremely useful for
measurements of surface variation such as run-out or allowable movement
between components such as endplay.

Typically, dial indicators need to be firmly mounted to a fixed surface or

component. This is accomplished by either a magnetic base or, as shown in the
image above, a pair of vise grip pliers.

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Use this space to write any questions you may have for your instructor.

NOTES:

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