VALVE CLEARANCE > ADJUSTMENT

for Preparation Click here



1. REMOVE ENGINE ROOM SIDE LH COVER


    A108719

  1. Using a clip remover, remove the engine room side cover.



2. REMOVE ENGINE ROOM COVER SIDE


    A109835

  1. Remove the 5 clips and engine room cover side.



3. REMOVE FRONT WHEEL RH


4. REMOVE ENGINE UNDER COVER NO.1


    A108722

  1. Remove the 6 bolts, 2 screws, 2 clips and engine under cover.



5. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    A109417

  1. Remove the screw and separate the fender splash shield.



6. REMOVE FRONT FENDER APRON SEAL RH


    A108724

  1. Remove the 2 bolts, clip and fender apron seal RH.



7. DRAIN COOLANT

  1. Remove the radiator cap.

    CAUTION:
    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Drain the engine coolant by loosening the lower drain plug of the radiator and the cylinder block drain cock plugs.

    HINT:
    Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover.



  1. Tighten the cylinder block drain cock plugs.

    Torque:
    13 N*m{ 133 kgf*cm , 9 in.*lbf }



    A108260E01



8. DRAIN ENGINE OIL

  1. Remove the oil filler cap.

  1. Remove the oil drain plug, and drain the oil into a container.

  1. Clean and install the oil drain plug with a new gasket.

    Torque:
    45 N*m{ 459 kgf*cm , 33 ft.*lbf }



9. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

  1. Remove the 2 nuts and the front wiper arm and blade assembly RH.



10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

  1. Remove the nut and the front wiper arm and blade assembly LH.



11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    E110470

  1. Remove the 2 clips.

  1. Disengage the 6 claws and the clamp, and remove the cowl top ventilator louver sub-assembly.



12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    I035808E01

  1. Using a screwdriver wrapped with protective tape, separate the rod of the windshield wiper link assembly from the front wiper motor as shown in the illustration.



    I035809E01

  1. Remove the nut and washer.

  1. Put the matchmarks on the crank arm and front wiper motor.



    I035810

  1. Remove the 3 bolts and front wiper motor from the windshield wiper link assembly.



13. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER


    A112528E01

  1. Separate the wire harness clamp and grommet (A).

  1. Remove the 4 shock absorber nuts (B).

  1. Remove the 4 bolts, 2 nuts and cowl top panel sub-assembly.

  1. Install the 4 shock absorber nuts.

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }



14. REMOVE COOL AIR INTAKE DUCT SEAL

  1. Remove the 4 clips and cool air intake duct seal.



15. REMOVE AIR CLEANER CAP W/ INLET


    A108124

  1. Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

  1. Remove the air cleaner filter element from the air cleaner case.



16. REMOVE AIR CLEANER CASE W/ RESONATOR


    A109893

  1. Separate the ventilation hose No.2.



    A109270

  1. Disconnect the MAF meter connector.

  1. Disconnect the 2 wire harness clamps from the air cleaner.



    A106878

  1. Remove the 5 bolts from the air cleaner case w/ resonator.



    A109570

  1. Remove the hose clamp, and separate the air cleaner hose No.1.

  1. Remove the air cleaner case w/ resonator.



17. REMOVE EMISSION CONTROL VALVE SET


    A109272E01

  1. Disconnect the VSV connector (A).

  1. Remove the wire harness clamp (B).

  1. Disconnect the fuel vapor feed hose No. 1 (C).

  1. Disconnect the fuel vapor feed hose No. 2 (D).

  1. Remove the 2 nuts (E), then remove the emission control valve set.



18. REMOVE INTAKE AIR SURGE TANK


    A106879E03

  1. Disconnect the throttle motor connector (A).

  1. Separate the water by-pass hose No. 2 (B).

  1. Separate the water by-pass hose No. 3 (C).

  1. Separate the fuel vapor feed hose (D).



    A109268

  1. Disconnect the ventilation hose.



    A109273E01

  1. Remove the 2 bolts, then remove the engine hanger No.1 (A).

  1. Remove the 2 bolts, then remove the surge tank stay No. 1 (B).

  1. Remove the 2 bolts, then remove the surge tank stay No. 2 (C).



    A109274E01

  1. Disconnect the ground cable connector.

  1. Using a socket hexagon wrench 8 mm, remove the 4 bolts.

  1. Remove the 2 nuts, then remove the emission control valve bracket and the intake air surge tank.

  1. Remove the gasket from the intake air surge tank.



19. DISCONNECT RADIATOR HOSE INLET


20. REMOVE IGNITION COIL ASSEMBLY


21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    A078541E01

  1. Remove the 2 engine wire harness clamps.

  1. Remove the 3 nuts and disconnect the engine wire harness.



    A108160

  1. Remove the 9 bolts and the cylinder head cover.



22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    A036719E01

  1. Using an E6 "torx" socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.



    A114812

  1. Remove the 2 engine wire harness clamps.

    CAUTION:
    Wear insulating gloves.



    A108125

  1. Remove the 2 bolts and 2 brackets.



    A108159

  1. Remove the 9 bolts and the cylinder head cover.



23. INSPECT VALVE CLEARANCE


    A108135

  1. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No.1 timing belt cover.

  1. 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.



    A078666E01

  1. 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.



    A078667E01

  1. 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.



    A078668E01

  1. 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.



24. ADJUST VALVE CLEARANCE


    A078669E01

  1. Turn the camshaft so that the cam lobe faces upward.

  1. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.



    A078670E01

  1. 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:
    1. Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
    2. 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 (A)
    		09248-05410
    SST (B)
    		09248-05420



    A078671E01

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



    EM00494E01

  1. Using a micrometer, measure the thickness of the removed shim.

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



  1. 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:
    1. 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.).
    2. Refer to new shim thickness table below.



    V000719E03

    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.) 
    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.



    V000720E03

    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.) 
    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.



    A078672E01

  1. Place a new adjusting shim on the valve lifter with imprinted number facing down.

  1. Press down the valve lifter with SST (A), and remove SST (B).

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

  1. Recheck the valve clearance.



25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    A078673E01

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

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes after applying seal packing.
    3. Do not start the engine within 2 hours after installing.



    A108160

  1. 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 }



    A078541

  1. Install the engine wire harness with the 3 nuts and 2 clamps.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    A078674E01

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

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes after applying seal packing.
    3. Do not start the engine within 2 hours after installing.



    A108159

  1. 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 }



    A108125

  1. Install the 2 brackets with the 2 bolts.



    A114812

  1. Install the 2 engine wire harness clamps.

    CAUTION:
    Wear insulating gloves.



    A036719

  1. 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 }



27. INSTALL IGNITION COIL ASSEMBLY

Torque:
8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



28. CONNECT RADIATOR HOSE INLET


29. INSTALL INTAKE AIR SURGE TANK

  1. Install a new gasket to the intake air surge tank.



    A109274E02

  1. Using a socket hexagon wrench 8 mm, install the intake manifold with the 4 bolts and 2 nuts . Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

  1. Connect the ground cable connector.



    A109273E02

  1. Install the surge tank stay No. 2 (A) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the surge tank stay No. 1 (B) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the engine hunger No. 1 (C) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }



    A109268

  1. Connect the ventilation hose.



    A106879E02

  1. Connect the fuel vapor feed hose (A).

  1. Connect the water by-pass hose No.3 (B).

  1. Connect the water by-pass hose No.2 (C).

  1. Connect the throttle motor connector (D).



30. INSTALL EMISSION CONTROL VALVE SET


    A109272E02

  1. Install the emission control valve set with the 2 nuts (A).

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

  1. Connect the fuel vapor feed hose No.2 (B).

  1. Connect the fuel vapor feed hose No.1 (C).

  1. Connect the wire harness clamp (D).

  1. Connect the VSV connector (E).



31. INSTALL AIR CLEANER CASE W/ RESONATOR


    A109267

  1. Install the air cleaner hose No.1 to the throttle body assembly with the hose clamp.



    A106878

  1. Install the air cleaner case w/ resonator with the 5 bolts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



    A109270

  1. Connect the MAF meter connector.

  1. Connect the 2 wire harness clamps to the air cleaner.



    A109893

  1. Connect the ventilation hose No.2.



32. INSTALL AIR CLEANER CAP W/ INLET

  1. Install the air cleaner filter element to the air cleaner case.



    A108124

  1. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



33. INSTALL COOL AIR INTAKE DUCT SEAL

  1. Install the 4 clips and cool air intake duct seal.



34. INSTALL COWL TOP PANEL SUB-AEEMBLY OUTER

  1. Remove the 4 shock absorber nuts.



    A112528E01

  1. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).



35. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    E110471

  1. Install the windshield wiper motor and link assembly with the 5 bolts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

  1. Connect the connector.



36. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


37. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    B108016E03

  1. Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069045E01

  1. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.



38. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    B108016E03

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069046E01

  1. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.



39. ADD ENGINE OIL


40. ADD COOLANT

  1. Tighten the lower drain plug of the radiator.

  1. Loosen the upper drain plug of the radiator.



    A080492E01

  1. Install a vinyl tube to the vent plug located on the upper drain plug.

  1. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

  1. Tighten the upper drain plug.

    CAUTION:
    1. Do not use an alcohol type coolant or plain water alone.
    2. The coolant must be mixed with plain water (preferably de-mineralized water).

      Capacity:
      9.7 liters (10.3 US qts, 8.5 lmp.qts)

    HINT:
    1. Improper coolants may damage engine cooling system.
    2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
    3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
    4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.

  1. Install the radiator cap securely.

  1. Fill the radiator reservoir tank with coolant.

  1. Warm up the engine.

    HINT:
    Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

  1. Stop the engine and wait until the coolant cools down.

  1. Remove the radiator cap and check the coolant level inside the radiator.

  1. If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

  1. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.



41. CHECK FOR ENGINE COOLANT LEAKS


A078989

CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Fill the radiator with coolant and attach a radiator cap tester.

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.



42. CHECK FOR ENGINE OIL LEAKS


43. INSTALL FRONT FENDER APRON SEAL RH


    A108724

  1. Install the 2 bolts, clip and fender apron seal RH.



44. INSTALL FRONT FENDER SPLASH SHILD SUB-ASSEMBLY RH


    A109416

  1. Install the fender splash shield with the screw.



45. INSTALL ENGINE UNDER COVER NO.1


    A108722

  1. Install the 6 bolts, 2 screws, 2 clips and engine under cover.



46. INSTALL FRONT WHEEL RH


47. INSTALL ENGINE ROOM COVER SIDE


    A109835

  1. Install the 5 clips and engine room cover side



48. INSTALL ENGINE ROOM SIDE LH COVER


    A108719

  1. Fit the clips and install the engine room side LH cover.