VALVE CLEARANCE ADJUSTMENT


  1. REMOVE FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  2. REMOVE FUEL PUMP ASSEMBLY (for Bank 2)

    Click here

  3. DISCONNECT WIRE HARNESS


    1. A01628L

      Remove the 3 connectors and connector clamp.

    2. A0160ZG

      Using a screwdriver, detach the claw and disconnect the No. 4 connector holder.

    3. A016370

      Disconnect the 5 connectors and grommet from the engine room ECU box.

    4. A01608K

      Disconnect the 8 connectors and 3clamps.

    5. A0163JO

      Disconnect the 5 connectors and 7clamps.

    6. Remove the 2 bolts and disconnect the 2 ground wires.

    7. Remove the No. 1 engine room relay block cover (for RHD).

    8. A015YZ0

      Remove the nut (for RHD).

    9. A015YHC

      Disconnect the clamp, detach the 2 claws and disconnect the wire harness from the engine room No. 1 relay block (for RHD).

    10. A016393

      Remove the bolt, and disconnect the ground cable.

    11. A01638W

      Remove the bolt, and disconnect the clamp and ground cable.

  4. REMOVE IGNITION COIL ASSEMBLY


    1. Disconnect the 8 ignition coil connectors.

    2. A0160Z7E01

      Remove the 8 bolts and 8 ignition coil assemblies.

      Note

      Do not damage the ignition coil assemblies when removing them.

  5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1)


    1. A0163HNE01

      Remove the fuel pump spacer gasket.

    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

      Tech Tips

      Make sure that the removed parts are returned to the original places they were removed from.

    3. A0161DZ

      Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A01604XE01

      Remove the fuel pump spacer gasket.

    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      Tech Tips

      Make sure that the removed parts are returned to the original places they were removed from.

    3. A015Z76

      Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.

  7. REMOVE OIL REFLECTOR PLATE LH (for Bank 1)


    1. A0161NQ

      Remove the 2 bolts and oil reflector plate LH from the cylinder head assembly LH.

  8. REMOVE OIL REFLECTOR PLATE RH (for Bank 2)


    1. A0162QZ

      Remove the 2 bolts and oil reflector plate RH from the cylinder head assembly.

  9. INSPECT NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Rotate the crankshaft clockwise to set the No. 1 cylinder to TDC compression by aligning the crankshaft pulley timing mark (notch) with the timing chain cover 0° position.

      A0162UWE01

    2. Check that each timing mark is positioned as shown in the illustration.

      Tech Tips

      If the timing marks are not positioned as shown in the illustration, rotate the crankshaft 360° to align the timing marks.

  10. INSPECT VALVE CLEARANCE


    1. Using a feeler gauge, measure the clearance between the indicated valve rocker arms and camshafts.

      A0162BXE01
      Standard Valve Clearance (Cold)
      Item Specified Condition
      Intake 0.12 to 0.18 mm (0.00472 to 0.00709 in.)
      Exhaust 0.22 to 0.28 mm (0.00866 to 0.0110 in.)

      Tech Tips


      • On this engine, valve clearance is measured between the valve rocker arms and the camshaft lobes. The shims used to adjust the valve clearance are located on the top of the valve stems.

      • The valve clearance shown in the Standard Valve Clearance table is the clearance as measured between the cam lobe and valve rocker arm.

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

    2. Turn the crankshaft 1 revolution (360°) to set the No. 6 cylinder to TDC compression.

    3. Using a feeler gauge, measure the clearance between the indicated valve rocker arms and camshafts.

      A0160UGE01
      Standard Valve Clearance (Cold)
      Item Specified Condition
      Intake 0.12 to 0.18 mm (0.00472 to 0.00709 in.)
      Exhaust 0.22 to 0.28 mm (0.00866 to 0.0110 in.)

      Tech Tips


      • On this engine, valve clearance is measured between the valve rocker arms and the camshaft lobes. The shims used to adjust the valve clearance are located on the top of the valve stems.

      • The valve clearance shown in the Standard Valve Clearance table is the clearance as measured between the cam lobe and valve rocker arm.

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

  11. ADJUST VALVE CLEARANCE


    1. Remove the timing chain cover sub-assembly Click here.

    2. Remove the camshaft Click here.

    3. A015ZU2E01

      Raise the valve rocker arm above the shim being replaced, and remove the valve adjusting shim.

      Note


      • Be careful not to drop the adjusting shim into the cylinder head.

      • To prevent damage, do not attempt to adjust valve clearance by tightening or loosening the valve rocker arm pivots.

      Tech Tips

      Arrange the removed parts in the correct order.

    4. A0161YWE01

      Using a dial gauge, measure the thickness of the existing valve adjusting shim after removing it.

      Tech Tips

      Be careful not to measure at the valve adjusting shim center groove.

    5. Determine the replacement valve adjusting shim thickness according to the formula or charts below.


      1. Calculate the thickness of the replacement valve adjusting shim so that the valve clearance comes within the specified value.

        T2 Thickness of replacement shim
        T1 Thickness of existing shim
        A Measured valve clearance
        Valve clearance
        Intake
        T2 = T1 + (A - 0.15 mm (0.0059 in.)) x 1.8
        Exhaust
        T2 = T1 + (A - 0.25 mm (0.0098 in.)) x 1.6

        This example is provided only as a calculation example, based on the clearance adjustment of an intake valve. If non-metric units are being used, substitute those measurements for the values shown below.

        Step 1 - Determining the amount of excess clearance


        • The specified clearance (0.15) is subtracted from the measured value (0.40), and the result is then multiplied by the rocker ratio compensation value (1.8).


        • (Measured value - specification) x compensation value = amount of excess clearance


        • (0.40 - 0.15) x 1.8 = 0.450

        Step 2 - Using the existing valve adjusting shim to determine the required thickness of the replacement valve adjusting shim


        • The amount of excess clearance (0.450) is added to the thickness of the existing valve adjusting shim (2.300). The resulting value is the ideal thickness of a replacement valve adjusting shim.


        • Excess clearance + thickness of existing shim = thickness of ideal replacement shim


        • 0.450 + 2.300 = 2.750

        Step 3 - Select the valve adjusting shim closest to the thickness of the ideal replacement shim


        • Compare the thickness of the available replacement valve adjusting shims to the ideal replacement shim and choose the shim that is the closest match.


        • Closest replacement valve adjusting shim = 2.750 (Select a new No. 74 shim.)

        Tech Tips


        • Select a replacement shim with a thickness as close to the calculated value as possible.

        • Shims are available in 41 sizes in increments of 0.020 mm (0.0008 in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.).

        • To select a replacement valve adjusting shim, refer to the following Valve Adjusting Shim Selection Chart and New Shim Thickness tables.

        A0162DGE01
        Intake valve clearance (Cold)
        0.12 to 0.18 mm (0.00472 to 0.00709 in.)

        EXAMPLE:

        If the existing shim (installed shim) is 2.300 mm (0.0906 in.), and the measured clearance is 0.39 mm (0.0154 in.), then a new 2.740 mm (0.1079 in.) No. 74 shim should be used as a replacement for the existing shim.

        New Shim Thickness mm (in.)
        Shim No. Thickness Shim No. Thickness Shim No. Thickness
        00 2.000 (0.0787) 28 2.280 (0.0898) 56 2.560 (0.1008)
        02 2.020 (0.0795) 30 2.300 (0.0906) 58 2.580 (0.1016)
        04 2.040 (0.0803) 32 2.320 (0.0913) 60 2.600 (0.1024)
        06 2.060 (0.0811) 34 2.340 (0.0921) 62 2.620 (0.1031)
        08 2.080 (0.0819) 36 2.360 (0.0929) 64 2.640 (0.1039)
        10 2.100 (0.0827) 38 2.380 (0.0937) 66 2.660 (0.1047)
        12 2.120 (0.0835) 40 2.400 (0.0945) 68 2.680 (0.1055)
        14 2.140 (0.0843) 42 2.420 (0.0953) 70 2.700 (0.1063)
        16 2.160 (0.0850) 44 2.440 (0.0961) 72 2.720 (0.1071)
        18 2.180 (0.0858) 46 2.460 (0.0969) 74 2.740 (0.1079)
        20 2.200 (0.0866) 48 2.480 (0.0976) 76 2.760 (0.1087)
        22 2.220 (0.0874) 50 2.500 (0.0984) 78 2.780 (0.1094)
        24 2.240 (0.0882) 52 2.520 (0.0992) 80 2.800 (0.1102)
        26 2.260 (0.0890) 54 2.540 (0.1000)
        A01610ME01
        Exhaust valve clearance (Cold)
        0.22 to 0.28 mm (0.00866 to 0.0110 in.)

        EXAMPLE:

        If the existing shim (installed shim) is 2.300 mm (0.0906 in.), and the measured clearance is 0.39 mm (0.0154 in.), then a new 2.520 mm (0.0992 in.) No. 52 shim should be used as a replacement for the existing shim.

        New Shim Thickness mm (in.)
        Shim No. Thickness Shim No. Thickness Shim No. Thickness
        00 2.000 (0.0787) 28 2.280 (0.0898) 56 2.560 (0.1008)
        02 2.020 (0.0795) 30 2.300 (0.0906) 58 2.580 (0.1016)
        04 2.040 (0.0803) 32 2.320 (0.0913) 60 2.600 (0.1024)
        06 2.060 (0.0811) 34 2.340 (0.0921) 62 2.620 (0.1031)
        08 2.080 (0.0819) 36 2.360 (0.0929) 64 2.640 (0.1039)
        10 2.100 (0.0827) 38 2.380 (0.0937) 66 2.660 (0.1047)
        12 2.120 (0.0835) 40 2.400 (0.0945) 68 2.680 (0.1055)
        14 2.140 (0.0843) 42 2.420 (0.0953) 70 2.700 (0.1063)
        16 2.160 (0.0850) 44 2.440 (0.0961) 72 2.720 (0.1071)
        18 2.180 (0.0858) 46 2.460 (0.0969) 74 2.740 (0.1079)
        20 2.200 (0.0866) 48 2.480 (0.0976) 76 2.760 (0.1087)
        22 2.220 (0.0874) 50 2.500 (0.0984) 78 2.780 (0.1094)
        24 2.240 (0.0882) 52 2.520 (0.0992) 80 2.800 (0.1102)
        26 2.260 (0.0890) 54 2.540 (0.1000)

    6. Install the camshaft Click here.

    7. Install the chain sub-assembly Click here.


      1. Install the chain sub-assembly (for Bank 2).

      2. Install the No. 1 chain vibration damper (for Bank 2).

      3. Install the chain tensioner slipper (for Bank 2).

      4. Install the No. 1 chain tensioner assembly (for Bank 2).

      5. Install the chain sub-assembly (for Bank 1).

      6. Install the No. 1 chain vibration damper (for Bank 1).

      7. Install the chain tensioner slipper (for Bank 1).

      8. Install the No. 1 chain tensioner assembly (for Bank 1).

      9. Tighten the camshaft timing gear assembly.

    8. Inspect the valve clearance again.

      Note

      Be sure to inspect the valve clearance with the chain cub-assembly installed. When rotating the camshaft without the chain sub-assembly installed, contact between the valves and pistons may occur.

      Tech Tips

      If the valve clearance is not as specified, readjust the valve clearance.

  12. INSTALL OIL REFLECTOR PLATE LH (for Bank 1)


    1. A0161NQ

      Install the oil reflector plate LH with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  13. INSTALL OIL REFLECTOR PLATE RH (for Bank 2)


    1. A0162QZ

      Install the oil reflector plate RH with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1)


    1. A0161DZ

      Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

    2. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

      Note

      Remove any oil from the contact surface.

    3. A0160RHE01

      Apply seal packing as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly LH.

    4. A0163HNE02

      Install the cylinder head cover sub-assembly LH with 3 new seal washers and the 16 bolts.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Install a new fuel pump spacer gasket.

  15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A015Z76

      Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    3. A0161LGE01

      Apply seal packing as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.

    4. A01604XE02

      Install the cylinder head cover sub-assembly with 3 new seal washers and the 16 bolts.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Install a new fuel pump spacer gasket.

  16. INSTALL IGNITION COIL ASSEMBLY


    1. A0160Z7E01

      Install the 8 ignition coil assemblies with the 8 bolts.

      Note

      Do not damage the ignition coil assemblies when installing them.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 8 ignition coil connectors.

  17. CONNECT WIRE HARNESS


    1. A015ZRQ

      Connect the ground wire with the bolt and clamp.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A016393

      Connect the ground cable with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 69 in.*lbf }
    3. A015ZJD

      Connect the wire to the engine room No. 1 relay block. (for RHD)

    4. Connect the clamp. (for RHD)

    5. A015YZ0

      Connect the wire harness with the nut. (for RHD)

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    6. Install the No. 1 engine room relay block cover. (for RHD)

    7. A0163JO

      Connect the 7 clamps and connect the 5 connectors.

    8. Install the 2 ground wires with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. A01608K

      Connect the 3 clamps and 8 connectors.

    10. A016370

      Connect the 5 connectors and grommet to the engine room ECU box.

    11. A015ZEV

      Engage the claw and connect the No. 4 connector holder to the engine room ECU box.

    12. A01628L

      Connect the 3 connectors and connector clamp.

  18. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  19. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

    Click here