Valve Clearance: Adjustment

1. Drain the engine coolant (See COOLANT ).

1. Remove the FR wiper arm RH (See FRONT WIPER MOTOR ).

1. Remove the FR wiper arm LH (See FRONT WIPER MOTOR ).

1. Remove the cowl top ventilator louver sub-assembly (See FRONT WIPER MOTOR ).

1. Remove the windshield wiper link assembly (See FRONT WIPER MOTOR ).

1. Remove the cowl top panel sub-assembly (See REMOVAL ).

1. w/ engine under cover assembly

1. Remove the front fender apron seal RH (See REMOVAL ).

1. Using socket hexagon wrench 5, remove the 3 nuts.
2. Remove the V-bank cover.

1. Remove air cleaner cap sub-assembly (See REMOVAL ).

Fig 1: Removing V-Bank Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.
   Fig 2: Disconnecting VSV Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the fuel vapor feed hose No. 1.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 2 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts, then remove the emission control valve set.

Fig 3: Disconnecting Fuel Vapor Feed Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the throttle motor connector.
2. Disconnect the water by-pass hose No. 3.
3. Disconnect the water by-pass hose No. 2.
4. Disconnect the union to check valve hose.
   Fig 4: Disconnecting Throttle Motor Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the ventilation hose.
   Fig 5: Disconnecting Ventilation Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 3 nuts and separate the pressure feed tube.
   Fig 6: Removing Pressure Feed Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 2 bolts, then remove the engine hunger No. 1.
8. Remove the 2 bolts, then remove the surge tank stay No. 1.
9. Remove the 2 bolts, then remove the surge tank stay No. 2.
   Fig 7: Removing Surge Tank Stay

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using socket hexagon wrench 8, remove the 4 bolts.
11. Remove the 2 nuts, then remove the emission control valve bracket and the intake air surge tank.
12. Remove the gasket from the intake air surge tank.

Fig 8: Removing Emission Control Valve Bracket And Intake Air Surge Tank

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 engine wire harness clamps.
2. Remove the 3 nuts and disconnect the engine wire harness.
3. Remove the 9 bolts and the cylinder head cover.

Fig 9: Disconnecting Engine Wire Harness

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using an E6 torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
2. Remove the 9 bolts and the cylinder head cover.

Fig 10: Disconnecting Engine Wire Harness Protector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No. 1 timing belt cover.
2. Check that the valve lifters on the No. 1 (IN and EX) are both loose.

   If not, turn the crankshaft 1 revolution (360°) and align the mark as above.

   Fig 11: Aligning Timing Notch With Timing Mark "0" Of No 1 Timing Belt Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the valves indicated in the illustration on the left.
   1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold): 

      Intake 0.15 to 0.25 mm (0.0059 to 0.0098 in.) 

      Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 in.) 

   2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   Fig 12: Identifying Valves For Measuring Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
   1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold): 

      Intake 0.15 to 0.25 mm (0.0059 to 0.0098 in.) 

      Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 in.) 

   2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   Fig 13: Identifying Valves For Measuring Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
   1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold): 

      Intake 0.15 to 0.25 mm (0.0059 to 0.0098 in.) 

      Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 in.) 

   2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   Fig 14: Identifying Valves For Measuring Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Turn the camshaft so that the cam lobe faces upward.
2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
   Fig 15: Turning Valve Lifter With Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter.

   Remove SST (A).

   SST 09248-55040 (09248-05410, 09248-05420) 

   HINT:

   • Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
   • When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle.
   SST SPECIFICATION
   
   

   SST (A)	09248-05410
   SST (B)	09248-05420

   Fig 16: Placing SST (B) Between Camshaft And Valve Lifter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a small screwdriver and magnetic finger, remove the adjusting shim.
   Fig 17: Removing Adjusting Shim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a micrometer, measure the thickness of the removed shim.
6. Calculate the thickness of a new shim so the valve clearance comes within the specified value.
   SHIM THICKNESS REFERENCE
   
   

   A	Thickness of new shim
   B	Thickness of used shim
   C	Measured valve clearance

   Specified value (Cold): 

   Intake A = B + (C - 0.20 mm (0.0079 in.)) 

   Exhaust A = B + (C - 0.30 mm (0.0118 in.)) 

   Fig 18: Checking Thickness Of Removed Shim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Select a new shim with a thickness as close as possible to the calculated values.
   Fig 19: Adjusting Shim Selection Chart (Intake)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 20: Adjusting Shim Selection Chart (Exhaust)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   ADJUSTING SHIM SELECTION EXAMPLE
   
   

   EXAMPLE (Intake):

   Measured valve clearance = 0.45 mm (0.0177 in.)

   0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)

   (Measured - Specification = Excess clearance)

   Used shim measurement = 2.80 mm (0.1102 in.)

   0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)

   (Excess clearance + Used shim = Ideal new shim)

   Closest new shim = 3.05 mm (0.1201 in.)

   Select No.12 shim

   HINT:

   • Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
   • Refer to new SHIM THICKNESS TABLE  on the next 2 pages.
8. Place a new adjusting shim on the valve lifter with imprinted number facing down.
9. Press down the valve lifter with SST (A), and remove SST (B).

   SST 09248-55040 (09248-05410, 09248-05420) 

10. Recheck the valve clearance.

Fig 21: Pressing Down Valve Lifter With SST (A) And Removing SST (B)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing to the cylinder head as shown in the illustration.

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not start the engine within 2 hours after installing.
2. Install the cylinder head cover with the 9 bolts.

   Tighten the bolts uniformly in several steps.

   Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

3. Install the engine wire harness with the 3 nuts.

Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

Fig 22: Applying Seal Packing To Cylinder Head

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing to the cylinder head as shown in the illustration.

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not start the engine within 2 hours after installing.
   Fig 23: Applying Seal Packing To Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cylinder head cover with the 9 bolts.

   Tighten the bolts uniformly in several steps.

   Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

3. Using an E6 torx socket wrench, install the engine wire harness protector with the 2 bolts.

Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and emission control valve bracket with the 2 nuts.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

3. Using a socket hexagon wrench 8, tighten the 4 bolts.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

4. Install the surge tank stay No. 2 with the 2 bolts.

   Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) 

5. Install the surge tank stay No. 1with the 2 bolts.

   Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) 

6. Install the engine hunger No. 1 with the 2 bolts.

   Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) 

7. Install the pressure feed tube with the 3 nuts.

   Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water by-pass hose No. 2.
11. Connect the water by-pass hose No. 3.
12. Connect the throttle motor connector.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

1. Install the air cleaner cap sub-assembly (See INSTALLATION ).

1. Connect the vacuum hose (See INSTALLATION  ).

1. Fit the 2 retainers and install the V-bank cover.
2. Using a socket hexagon wrench 5, tighten the 3 nuts.

Torque: 7.9 N*m (81 kgf*cm, 70 in.*lbf) 

1. Install the cowl top panel sub-assembly (See INSTALLATION ).

1. Install the windshield wiper link assembly (See INSTALLATION ).

1. Install the cowl top ventilator louver sub-assembly (See INSTALLATION ).

1. Install the FR wiper arm LH (See INSTALLATION ).

1. Install FR wiper arm RH (See INSTALLATION ).

1. Add engine coolant (See COOLANT ).

1. Check for engine coolant leakage (See COOLING SYSTEM ).