Valve Clearance: Adjustment

REMOVE ENGINE ROOM SIDE LH COVER NO.2 (See REMOVAL )
REMOVE FRONT WHEEL RH
REMOVE ENGINE UNDER COVER NO.1 (See REMOVAL )
SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See REMOVAL )
REMOVE FRONT FENDER APRON SEAL RH (See REMOVAL )
DRAIN COOLANT (See COOLANT )
DRAIN ENGINE OIL (See OIL AND OIL FILTER )
REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (See REMOVAL )
REMOVE AIR CLEANER CAP VW INLET (See REMOVAL )
REMOVE AIR CLEANER CASE W/ RESONATOR (See REMOVAL )
REMOVE EMISSION CONTROL VALVE SET (See REMOVAL )
REMOVE INTAKE AIR SURGE TANK (See REMOVAL )
DISCONNECT RADIATOR HOSE INLET
REMOVE IGNITION COIL ASSEMBLY
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 2 engine wire harness clamps.
2. Remove the 3 nuts and disconnect the engine wire harness.
  
  Fig 1: Locating Engine Wire Harness Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 9 bolts and the cylinder head cover.
  
  Fig 2: Locating Cylinder Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Using an E6 "tone" socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
  
  Fig 3: Locating Bolts And Disconnecting Engine Wire Harness Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 engine wire harness clamps.
  CAUTION: Wear insulating gloves.
  
  Fig 4: Locating Engine Wire Harness Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and 2 brackets.
  
  Fig 5: Locating Brackets With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 9 bolts and the cylinder head cover.
  
  Fig 6: Locating Cylinder Head Cover And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE CLEARANCE
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 cylinder (IN and EX) are both loose.
  If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
  
  Fig 7: Aligning Timing Notch With Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the valves indicated in the illustration.
  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 8: Identifying Clearance Between Valve Lifter And Camshaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.
  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 9: Identifying Clearance Between Valve Lifter And Camshaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.
  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 10: Identifying Clearance Between Valve Lifter And Camshaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST VALVE CLEARANCE

Turn the camshaft so that the cam lobe faces upward.
Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.

Fig 11: Adjusting Valve Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 REFERENCE CHART

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

Fig 12: Pressing Down Valve Lifter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver and magnetic finger, remove the adjusting shim.

Fig 13: Removing Adjusting Shim
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the thickness of the removed shim.

Calculate the thickness of a new shim so the valve clearance comes within the specified value.

THICKNESS CHART

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 14: Checking Thickness Of Removed Shim

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a new shim with a thickness as close as possible to the calculated values.

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 below.

Fig 15: Adjusting Shim Selection Chart (Intake Valve)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Intake valve clearance (Cold):

0.15 to 0.25 mm (0.0059 to 0.0098 in.)

EXAMPLE:

The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 shim.

New shim thickness mm (in.)

THICKNESS CHART

Shim No.	Thickness	Shim No.	Thickness
1	2.500 (0.0984)	10	2.950 (0.1161)
2	2.550 (0.1004)	11	3.000 (0.1181)
3	2.600 (0.1024)	12	3.050 (0.1201)
4	2.650 (0.1043)	13	3.100 (0.1220)
5	2.700 (0.1063)	14	3.150 (0.1240)
6	2.750 (0.1083)	15	3.200 (0.1260)
7	2.800 (0.1102)	16	3.250 (0.1280)
8	2.850 (0.1122)	17	3.300 (0.1299)
9	2.900(0.1142)

HINT:

New shims have the thickness in millimeters imprinted on the face.

Fig 16: Adjusting Shim Selection Chart (Exhaust Valve)

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.0098 to 0.0138 in.)

EXAMPLE:

The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 10 shim.

New shim thickness mm (in.)

THICKNESS CHART

Shim No.	Thickness	Shim No.	Thickness
1	2.500 (0.0984)	10	2.950 (0.1161)
2	2.550 (0.1004)	11	3.000 (0.1181)
3	2.600 (0.1024)	12	3.050 (0.1201)
4	2.650 (0.1043)	13	3.100 (0.1220)
5	2.700 (0.1063)	14	3.150 (0.1240)
6	2.750 (0.1083)	15	3.200 (0.1260)
7	2.800 (0.1102)	16	3.250 (0.1280)
8	2.850 (0.1122)	17	3.300 (0.1299)
9	2.900 (0.1142)

HINT:

New shims have the thickness in millimeters imprinted on the face.

Place a new adjusting shim on the valve lifter with imprinted number facing down.
Press down the valve lifter with SST (A), and remove SST (B).
SST 09248-55040 (09248-05410, 09248-05420)

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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 18: Locating 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)
  
  Fig 19: Locating Cylinder Head Cover And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the engine wire harness with the 3 nuts and 2 clamps.
  Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
  
  Fig 20: Locating Engine Wire Harness, Nuts And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
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 21: Locating 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)
  
  Fig 22: Locating Cylinder Head Cover And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 brackets with the 2 bolts.
  
  Fig 23: Locating Brackets And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 engine wire harness clamps.
  CAUTION: Wear insulating gloves.
  
  Fig 24: Locating Engine Wire Harness Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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)
INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf)
CONNECT RADIATOR HOSE INLET
INSTALL INTAKE AIR SURGE TANK (See INSTALLATION )

Fig 25: Locating Engine Wire Harness Protector And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EMISSION CONTROL VALVE SET (See INSTALLATION )
INSTALL AIR CLEANER CASE W/ RESONATOR (See INSTALLATION )
INSTALL AIR CLEANER CAP W/ INLET (See INSTALLATION )
INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (See INSTALLATION )
ADD ENGINE OIL
ADD COOLANT (See COOLANT )
INSPECT FOR ENGINE COOLANT LEAK (See COOLING SYSTEM )
INSPECT FOR OIL LEAK
INSTALL FRONT FENDER APRON SEAL RH (See INSTALLATION )
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See INSTALLATION )
INSTALL ENGINE UNDER COVER NO.1 (See INSTALLATION )
INSTALL FRONT WHEEL RH
INSTALL ENGINE ROOM SIDE LH COVER NO.2 (See INSTALLATION )