ADJUSTMENT

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.

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.

Tighten the cylinder block drain cock plugs.

Torque:

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

Remove the oil filler cap.

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

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

Torque:

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

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

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

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

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

Remove the 4 shock absorber nuts (B).

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

Install the 4 shock absorber nuts.

Torque:

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

Remove the 4 clips and cool air intake duct seal.

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

Disconnect the 2 wire harness clamps from the air cleaner.

Remove the air cleaner case w/ resonator.

Remove the wire harness clamp (B).

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

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

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

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

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

Separate the fuel vapor feed hose (D).

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

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

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

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

Remove the gasket from the intake air surge tank.

Remove the 3 nuts and disconnect the engine wire harness.

CAUTION:

Wear insulating gloves.

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.

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.
   

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.
   

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.
   

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

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.
   

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

Specified value (Cold):

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

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

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

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.
   

Intake valve clearance (Cold):

0.15 to 0.25 mm (0.0059 to 0.0098 in.)

HINT:

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

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.0098 to 0.0138 in.)

HINT:

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

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

SST

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

Recheck the valve clearance.

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.
   

Torque:

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

Torque:

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

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.
   

Torque:

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

CAUTION:

Wear insulating gloves.

Torque:

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

Install a new gasket to the intake air surge tank.

Torque:

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

Connect the ground cable connector.

Torque:

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

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

Torque:

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

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

Torque:

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

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

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

Connect the throttle motor connector (D).

Torque:

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

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

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

Connect the wire harness clamp (D).

Connect the VSV connector (E).

Torque:

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

Connect the 2 wire harness clamps to the air cleaner.

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

Torque:

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

Install the 4 clips and cool air intake duct seal.

Remove the 4 shock absorber nuts.

Torque:

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

Install the 4 shock absorber nuts (B).

Torque:

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

Install the wire harness clamp and grommet (A).

Torque:

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

Connect the connector.

Clean the wiper arm serrations.

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

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

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

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

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

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

Tighten the lower drain plug of the radiator.

Loosen the upper drain plug of the radiator.

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

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.
   

Install the radiator cap securely.

Fill the radiator reservoir tank with coolant.

Warm up the engine.

HINT:

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

Stop the engine and wait until the coolant cools down.

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

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.

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

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

Warm up the engine.

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.