VALVE CLEARANCE ADJUSTMENT


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE NO. 3 ENGINE UNDER COVER

    A01181U

    1. Remove the 3 clips and the No. 3 engine under cover.

  3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A011AQSE01
      Text in Illustration
      *1 Wire harness clamp
      *2 Clamp

      Disconnect the connector and 2 wire harness clamps.

    2. Loosen the hose clamp and separate the air cleaner hose.

    3. Disengage the 2 clamps and 2 claws and remove the air cleaner cap.

  4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. A0118L6

      Remove the air cleaner filter element.

  5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A011AXX

      Remove the 3 bolts and the air cleaner case.

  6. REMOVE AIR CLEANER HOSE ASSEMBLY

    A011AWO

    1. Remove the air cleaner hose.

  7. REMOVE ENGINE COVER ASSEMBLY


    1. A011ACJ

      Disengage the 3 claws and remove the engine cover.

  8. SEPARATE ENGINE WIRE

  9. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A011BP9E01
    Text in Illustration
    *1 Wooden Block

    1. Support the engine with a jack and a wooden block, as shown in the illustration.

    2. A01189N

      Remove the 5 bolts and 2 nuts.

    3. Remove the stud bolt from the engine mounting bracket.

    4. A0118ZQE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the engine mounting insulator.

  10. REMOVE VACUUM PUMP ASSEMBLY


    1. A01182F

      Slide the clip and disconnect the 2 vacuum hoses.

    2. A01184T

      Remove the 2 bolts and vacuum pump assembly.

    3. A0118DH

      Remove the 2 O-rings from the vacuum pump assembly.

  11. REMOVE NO. 2 CYLINDER HEAD COVER

    A0118TZ

    1. Remove the 2 bolts, 2 harness brackets and the No. 2 cylinder head cover.

    2. A011927

      Remove the 3 fuel pipe clamps.

    3. A011B2H

      Separate the fuel check valve from the No. 2 cylinder head cover.

    4. Remove the No. 2 cylinder head cover.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A011AHP

    1. Disconnect the vacuum hose.

    2. Remove the bolt and wire harness bracket.

    3. A011ABA

      Remove the 12 bolts and the cylinder head cover.

  13. CHECK VALVE CLEARANCE


    1. A011AYAE01
      Text in Illustration
      *1 Timing Mark
      *2 TDC Mark

      Set the No. 1 cylinder to TDC/Compression.


      1. Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump are aligned.

      2. Check that the timing mark of the camshaft timing sprocket is in the position shown in the illustration.

        Tech Tips

        If not, turn the crankshaft damper 1 revolution (360°) to align the timing mark and sprocket as above.

    2. A011BLOE03
      Text in Illustration
      *1 No. 1 Exhaust
      *2 No. 2 Intake
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearance of the No. 1 cylinder exhaust valve and the No. 2 cylinder intake valve.


      1. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.


        • Do not apply excessive force to the valve adjusting screw when using adjusting tools such as SST and a screwdriver.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    3. A011742E02
      Text in Illustration
      *1 No. 1 Intake
      *2 No. 3 Exhaust
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearance of the No. 1 cylinder intake valve and the No. 3 cylinder exhaust valve.


      1. Turn the crankshaft by a further 180° clockwise.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    4. A0119M4E02
      Text in Illustration
      *1 No. 3 Intake
      *2 No. 4 Exhaust
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearances of the No. 3 cylinder intake valve and No. 4 cylinder exhaust valve.


      1. Turn the crankshaft clockwise by a further 180°.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    5. A0118CVE02
      Text in Illustration
      *1 No. 2 Exhaust
      *2 No. 4 Intake
      *3 Camshaft
      *4 Feeler Gauge

      Check the valve clearances of the No. 2 cylinder intake valve and No. 4 cylinder intake valve.


      1. Turn the crankshaft clockwise by a further 180°.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

  14. ADJUST VALVE CLEARANCE


    1. A01195FE02
      Text in Illustration
      *1 Adjusting Screw
      *2 Lock Nut

      Using SST and a screwdriver, loosen the valve adjusting nut while keeping the valve adjusting screw in position.

      SST
      09248-56010
    2. A0118URE02
      Text in Illustration
      *1 Adjusting Screw
      *2 Lock Nut
      *3 Feeler Gauge

      Adjust valve clearance (intake side).


      1. Insert a feeler gauge (0.14 mm (0.006 in.)) between the camshaft and No. 1 valve rocker arm, and turn the valve adjusting screw to adjust it.

        Valve clearance (cold)
        0.14 mm (0.006 in.)
      2. A0119NNE02
        Text in Illustration
        *1 Adjusting Screw
        *2 Lock Nut

        Using SST and a screwdriver, tighten the valve adjusting nut while keeping the valve adjusting screw in position.

        Torque:
        With SST
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
        Without SST
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Tech Tips


        • This torque wrench value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with a fulcrum length of 150 mm (5.91 in.) Click here.

        • This torque value is effective when SST is parallel to a torque wrench.

    3. Adjust the valve clearance (exhaust side).

      Valve clearance (cold)
      0.17 mm (0.007 in.)

      Tech Tips

      Perform the same procedure as for the intake valve clearance adjustment.

  15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0118TYE01

      Apply seal packing to the 4 locations as shown in the illustration, and then install the cylinder head cover.

      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 within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. A011ABAE01

      Temporarily tighten the cylinder head cover with the 12 bolts.

    3. Fully tighten the 12 bolts, as shown in the illustration.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    4. A011AHP

      Install the wire harness bracket.

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

    5. Connect the vacuum hose.

  16. INSTALL NO. 2 CYLINDER HEAD COVER

    A011BHY

    1. Install the No. 2 cylinder head cover.

    2. Install the fuel check valve onto the No. 2 cylinder head cover.

    3. A011927

      Install the 3 fuel pipe clamps.

    4. A0118TZ

      Install the No. 2 cylinder head cover with the 2 bolts and 2 harness brackets.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  17. INSTALL VACUUM PUMP ASSEMBLY


    1. A0118DH

      Coat 2 new O-rings with engine oil, and place them onto the vacuum pump assembly.

    2. A0119VCE01

      Install the vacuum pump assembly so that the coupling teeth A on the side of the vacuum pump can engage with the tip groove of camshaft B.

    3. A01184T

      Install 2 new bolts onto the vacuum pump assembly.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01182F

      Connect the 2 vacuum hoses with the clip to the vacuum pump assembly.

  18. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A0119RZ

    1. Engage the claw and install the engine mounting insulator.

    2. A01189NE01

      Install the stud bolt to the engine mounting bracket.

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

    3. Temporarily tighten the engine mounting insulator with the 5 bolts and 2 nuts.

    4. Fully tighten the 3 bolts to the body, as shown in the illustration.

      Torque:
      Bolt A
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    5. Fully tighten the 2 bolts and 2 nuts to the engine.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  19. CONNECT ENGINE WIRE

  20. INSTALL ENGINE COVER ASSEMBLY


    1. A011ACJ

      Engage the 3 claws and install the engine cover.

  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A011AXX

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  22. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. A011BX8

      Install the air cleaner filter element.

      Note

      Engage the air cleaner filter element protrusion with the air cleaner case groove.

  23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A0119FRE01

      Engage the 2 claws and 2 clamps and install the air cleaner cap.

    2. Connect the connector and 2 wire harness clamps.

      Text in Illustration
      *1 Wire harness clamp
      *2 Clamp
    3. A0118S5E01

      Connect the air cleaner hose to the air cleaner cap.

      Tech Tips


      • The clamp should contact the air cleaner hose stopper.

      • Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.

  24. INSTALL AIR CLEANER HOSE ASSEMBLY

    A0119ZOE02
    Text in Illustration
    *1 Paint Mark

    1. Install the air cleaner hose.

      Note

      Position the clip so that the claws are centered over the paint mark on the hose.

  25. INSTALL NO. 3 ENGINE UNDER COVER

    A01181U

    1. Install the No. 3 engine under cover with the 3 clips.

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 ft.*lbf }