Toyota Yaris: Balanceshaft / On-vehicle Inspection

ON-VEHICLE INSPECTION

PROCEDURE

1. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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2. DRAIN ENGINE OIL

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3. DRAIN ENGINE COOLANT

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4. REMOVE FAN AND GENERATOR V BELT

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5. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

(a) Slide the clip and separate the No. 6 water by-pass hose.

(b) Slide the clip and separate the No. 5 water by-pass hose.

(c) Remove the bolt, 2 nut and oil filter bracket sub-assembly from the cylinder block sub-aseembly.

6. SEPARATE COMPRESSOR WITH PULLEY ASSEMBLY

(a) Remove the 2 bolts and separate the compressor with pulley assembly.

7. SEPARATE NO. 4 CYLINDER BROCK INSULATOR

(a) Remove the bolt and separate the No. 4 cylinder brock insulator.

8. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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9. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 2 bolts.

(b) Remove the 13 bolts.

(c) Using a screwdriver, remove the oil pan sub-assembly by prying between the oil pan sub-assembly and crankshaft bearing cap assembly at the places shown in the illustration. NOTICE: Be careful not to damage the contact surfaces of the crankshaft bearing cap sub-aseembly and oil pan sub-assembly..

(d) Remove the 2 o-rings from the crankshaft bearing cap assembly.

10. INSPECT BALANCESHAFT BACK LASH

(a) Install a dial indicator and magnetic base.

(b) Set the tip of the dial indicator to the position shown in the illustration.

(c) Push the balance shaft gear to one side and set the dial indicator to 0 point with the backlash blocked.

(d) Move the balance shaft gear by hand and measure the backlash with the dial indicator.

Standard Diameter:

0.055 to 0.105 mm (0.00217 to 0.00413 in.)

11. ADJUST BALANCESHAFT BACK LASH

(a) Remove the engine balancer assembly.

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(b) Remove the balanceshaft housing spacer.

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(c) If the result is not within the specified range, select balanceshaft housing spacer that are thicker or thinner as necessary.

(d) Install the balanceshaft housing spacer.

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(e) Install the engine balancer assembly.

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12. INSTALL OIL PAN SUB-ASSEMBLY

(a) Install the new 2 o-ring to the crankshaft bearing cap sub-assembly.

(b) Apply seal packing in a continuous line as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Packing Dimension: Area Specified Condition Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) NOTICE: Remove any oil from the contact surfaces. Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing. Do not add engine oil for at least 2 hours after the installation. Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).

*a Seal Packing

(c) Temporarily install the oil pan sun-assembly with the 13 bolts. Bolt Length Bolt (A) 70 mm (2.76 in.) Bolt (B) 30 mm (1.18 in.)

(d) Tighten the 13 bolts in the order shown in the illustration to install the oil pan sub-assembly. Torque: 25 N·m {255 kgf·cm}

(e) Tighten the 2 bolts. Torque: 46 N·m {469 kgf·cm}

13. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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14. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY

(a) Tighten the 2 bolts and connect the compressor with pulley assembly..

Torque:

25 N·m {255 kgf·cm}

15. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

(a) Install the new 2 o-ring.

(b) Install the bolt, 2 nuts and oil filter bracket sub-assembly to the oil pan sub-assembly.

Torque:

21 N·m {214 kgf·cm}

(c) Install the No. 5 water by-pass hose and slide the 2 clips to secure it.

(d) Install the No. 6 water by-pass hose and slide the 2 clips to secure it.

16. INSTALL FAN AND GENERATOR V BELT

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17. ADD ENGINE COOLANT

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18. ADD ENGINE OIL

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19. INSPECT FOR ENGINE OIL LEAK

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20. INSPECT COOLANT LEAKS

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21. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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22. INSPECT ENGINE OIL LEVEL

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23. INSPECT ENGINE COOLANT QUALITY

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