VALVE CLEARANCE ADJUSTMENT


  1. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)


    1. A01KHOR

      Remove the seat track cover.

    2. Remove the 4 bolts.

    3. Remove the front seat assembly RH.

  2. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  3. SEPARATE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  4. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Remove the front door scuff.

    2. Remove the floor mat.

    3. Remove the 7 bolts and the engine service hole sub-cover.

  5. REMOVE THROTTLE CONTROL CABLE SUPPORT

    Tech Tips

    Remove the throttle control cable support with the accelerator flexible wire connected.

  6. REMOVE INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Remove the 3 nuts and bolt, intake air connector and gasket.

  7. REMOVE INTAKE AIR CONNECTOR BRACKET

  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  9. REMOVE CYLINDER HEAD COVER NO.2 (w/ Cylinder Head Cover No. 2)


    1. Remove the 4 nuts, plate washers, cylinder head cover No. 2 and cylinder head cover silencer.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.

  11. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. A01KGAA

      Turn the crankshaft pulley and align its groove with timing pointer.

    2. Check that the valve lifters on the No.1 cylinder are loose and valve lifters on the No. 4 are tight.

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

  12. INSPECT VALVE CLEARANCE


    1. A01KHO3E01
      Text in Illustration
      *1 No. 1 EX
      *2 No. 1 IN
      *3 No. 2 IN
      *4 No. 3 EX

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      2. Record the out - of - specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

        Valve clearance (Cold)
        Intake 0.20 - 0.30 mm (0.008 - 0.012 in.)
        Exhaust 0.40 - 0.50 mm (0.016 - 0.020 in.)
    2. A01KF5HE01
      Text in Illustration
      *1 No. 2 EX
      *2 No. 3 IN
      *3 No. 4 EX
      *4 No. 4 IN

      Turn the crankshaft one revolution (360°) and align the mark as above. (See procedure in step 11)

    3. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))

      Valve clearance (Cold)
      Intake 0.20 - 0.30 mm (0.008 - 0.012 in.)
      Exhaust 0.40 - 0.50 mm (0.016 - 0.020 in.)

  13. ADJUST VALVE CLEARANCE

    A01KF99E01

    1. Remove the adjusting shim.


      1. Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve points upward.

      2. Using SST, press down the valve lifter.

        SST
        09248-64011

      3. Position the notch of the valve lifter facing the exhaust manifold side.

    2. A01KFCS

      Remove the adjusting shim with a small screwdriver and magnetic finger.

    3. A01KG8Q

      Determine the replacement adjusting shim size by following the Formula or Charts:


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

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

        T = Thickness of removed shim

        A = Measured valve clearance

        N = Thickness of new shim

        Intake N = T + (A - 0.25 mm (0.010 in.))
        Exhaust N = T + (A - 0.45 mm (0.018 in.))

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

        Tech Tips

        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.).

        A01KH4NE01
        Intake valve clearance (Cold)
        0.20 - 0.30 mm (0.008 - 0.012 in.)
        EXAMPLE
        The 2.800 mm (0.1102 in.) shim is installed and the measured clearance is 0.350 mm (0.0138 in.). Replace the 2.800 mm (0.1102 in.) shim with a No. 21 shim.
        New shim thickness mm (in.)
        Shim No. Thickness Shim No. Thickness
        01 2.50 (0.0984) 46 2.95 (0.1161)
        42 2.55 (0.1004) 26 3.00 (0.1181)
        06 2.60 (0.1024) 47 3.05 (0.1201)
        43 2.65 (0.1043) 31 3.10 (0.1220)
        11 2.70 (0.1063) 48 3.15 (0.1240)
        44 2.75 (0.1083) 36 3.20 (0.1260)
        16 2.80 (0.1102) 49 3.25 (0.1280)
        45 2.85 (0.1122) 41 3.30 (0.1299)
        21 2.90 (0.1142) - -
        A01KEJSE01
        Exhaust valve clearance (Cold)
        0.40 - 0.50mm(0.016 - 0.020 in.)
        EXAMPLE
        The 2.800mm (0.1102 in.) shim is installed and the measured is 0.350 mm (0.0138 in.). Replace the 2.800 mm (0.1102 in.) shim with a No. 11 shim.
        New shim thickness mm (in.)
        Shim No. Thickness Shim No. Thickness
        01 2.50 (0.0984) 46 2.95 (0.1161)
        42 2.55 (0.1004) 26 3.00 (0.1181)
        06 2.60 (0.1024) 47 3.05 (0.1201)
        43 2.65 (0.1043) 31 3.10 (0.1220)
        11 2.70 (0.1063) 48 3.15 (0.1240)
        44 2.75 (0.1083) 36 3.20 (0.1260)
        16 2.80 (0.1102) 49 3.25 (0.1280)
        45 2.85 (0.1122) 41 3.30 (0.1299)
        21 2.90 (0.1142) - -
    4. A01KEK6E01

      Install a new adjusting shim.


      • Place a new adjusting shim on the valve lifter.

      • Remove the SST.

      SST
      09248-64011

  14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01KEP0E01
      Text in Illustration
      *a Seal Packing

      Remove any old packing (FIPG) material.

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    3. Install the gasket to the cylinder head cover.

    4. Install the cylinder head cover with 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

  15. INSTALL CYLINDER HEAD COVER NO.2 (w/ Cylinder Head Cover No. 2)


    1. Install the cylinder head cover silencer to the cylinder head cover.

    2. Install the cylinder head cover with the 4 plate washers and nuts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  16. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  17. INSTALL INTAKE AIR CONNECTOR BRACKET

    Torque:
    12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  18. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Install a new gasket to the intake manifold.

    2. Install the intake air connector with the 3 nuts and bolt.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  19. INSTALL THROTTLE CONTROL CABLE SUPPORT

    Torque:
    19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  20. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Torque:
    11.5 N*m  { 115 kgf*cm, 8.5 ft.*lbf }

  21. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  22. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  23. INSTALL FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)


    1. Temporarily install front side of the front seat assembly RH with the 2 bolts.

    2. Install the 2 rear side bolts.

      Torque:
      39.0 N*m  { 398 kgf*cm, 29 ft.*lbf }

    3. Tighten the 2 front side bolts.

      Torque:
      39.0 N*m  { 398 kgf*cm, 29 ft.*lbf }

    4. Install the seat track cover.