VALVE CLEARANCE(w/o Glow Plug Controller) ADJUSTMENT

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE FRONT WHEEL RH

  4. REMOVE NO. 1 ENGINE UNDER COVER (for Half Cover Type)

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  5. REMOVE NO. 1 ENGINE UNDER COVER (for Full Cover Type)

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  6. REMOVE REAR ENGINE UNDER COVER RH

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  7. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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  8. DISCONNECT ENGINE WIRE

    1. Disconnect the engine wire.

  9. REMOVE VACUUM PUMP ASSEMBLY

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  10. REMOVE HARNESS BRACKET

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  11. DISCONNECT SENSOR BRACKET

    1. A205769

      Remove the nut and disconnect the sensor bracket.

  12. REMOVE VENTILATION HOSE

    1. A210163

      Slide the 2 clips and remove the ventilation hose.

  13. REMOVE NO. 2 CYLINDER HEAD COVER

    1. A236901

      Remove the 3 fuel pipe clamps.

    2. A236902

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

    3. Remove the No. 2 cylinder head cover.

  14. REMOVE HARNESS BRACKET

    1. A236903

      Disconnect the vacuum hose.

    2. Remove the bolt and harness bracket.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A198335

      Remove the 12 bolts and cylinder head cover sub-assembly.

  16. CHECK VALVE CLEARANCE

    1. Set the No. 1 cylinder to TDC/Compression.

      1. A198346C02

        *a

        Timing Mark

        *b

        TDC Mark

        Turn the crankshaft damper sub-assembly until the grooves of the crankshaft damper sub-assembly and timing chain cover sub-assembly are aligned.

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

        Tip:

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

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

      1. A286811C03

        *1

        Camshaft

        *2

        No. 1 Valve Rocker Arm Sub-assembly

        *a

        View A

        *b

        for No. 1 Cylinder Exhaust Valve

        *c

        for No. 2 Cylinder Intake Valve

        *d

        Feeler Gauge

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

        Standard Valve Clearance (cold)

        Intake

        0.11 to 0.17 mm (0.00433 to 0.00669 in.)

        Exhaust

        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note:

        • Insert the feeler gauge with its center aligned with the center of the roller and parallel to the No. 1 valve rocker arm sub-assembly.

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

        Tip:

        If the clearance is not as specified, record the measurements, and then adjust the valve clearance.

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

      1. Turn the crankshaft 180° clockwise.

      2. A286812C03

        *1

        Camshaft

        *2

        No. 1 Valve Rocker Arm Sub-assembly

        *a

        View A

        *b

        for No. 1 Cylinder Intake Valve

        *c

        for No. 3 Cylinder Exhaust Valve

        *d

        Feeler Gauge

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

        Standard Valve Clearance (cold)

        Intake

        0.11 to 0.17 mm (0.00433 to 0.00669 in.)

        Exhaust

        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note:

        • Insert the feeler gauge with its center aligned with the center of the roller and parallel to the No. 1 valve rocker arm sub-assembly.

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

        Tip:

        If the clearance is not as specified, record the measurements, and then adjust the valve clearance.

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

      1. Turn the crankshaft 180° clockwise.

      2. A286813C03

        *1

        Camshaft

        *2

        No. 1 Valve Rocker Arm Sub-assembly

        *a

        View A

        *b

        for No. 3 Cylinder Intake Valve

        *c

        for No. 4 Cylinder Exhaust Valve

        *d

        Feeler Gauge

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

        Standard Valve Clearance (cold)

        Intake

        0.11 to 0.17 mm (0.00433 to 0.00669 in.)

        Exhaust

        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note:

        • Insert the feeler gauge with its center aligned with the center of the roller and parallel to the No. 1 valve rocker arm sub-assembly.

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

        Tip:

        If the clearance is not as specified, record the measurements, and then adjust the valve clearance.

    5. Check the valve clearance of the No. 2 cylinder exhaust valve and No. 4 cylinder intake valve.

      1. Turn the crankshaft 180° clockwise.

      2. A286814C03

        *1

        Camshaft

        *2

        No. 1 Valve Rocker Arm Sub-assembly

        *a

        View A

        *b

        for No. 2 Cylinder Exhaust Valve

        *c

        for No. 4 Cylinder Intake Valve

        *d

        Feeler Gauge

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

        Standard Valve Clearance (cold)

        Intake

        0.11 to 0.17 mm (0.00433 to 0.00669 in.)

        Exhaust

        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note:

        • Insert the feeler gauge with its center aligned with the center of the roller and parallel to the No. 1 valve rocker arm sub-assembly.

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

        Tip:

        If the clearance is not as specified, record the measurements, and then adjust the valve clearance.

  17. ADJUST VALVE CLEARANCE

    1. A286815C01

      *1

      Valve Adjusting Screw

      *2

      Valve Adjusting Nut

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

      09248-56010

    2. A286816C02

      *1

      Valve Adjusting Screw

      *2

      Valve Adjusting Nut

      *a

      Feeler Gauge

      Adjust valve clearance (intake side).

      1. Insert a feeler gauge (0.14 mm (0.00551 in.)) between the camshaft and No. 1 valve rocker arm sub-assembly, and turn the valve adjusting screw to adjust it.

        Valve Clearance (cold)

        0.14 mm (0.00551 in.)

      2. A295553C01

        *1

        Valve Adjusting Screw

        *2

        Valve Adjusting Nut

        *a

        Length of SST 150 mm (5.91 in.)

        *b

        Length of Torque Wrench 300 mm (11.81 in.)

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

        09248-56010

        without SST [Torque (N*m(kgf*cm, ft.*lbf))]

        20 N*m

        204 kgf*cm

        15 ft.*lbf

        with SST [Reading of Torque wrench (N*m(kgf*cm, ft.*lbf))]

        13 N*m

        133 kgf*cm

        10 ft.*lbf

        Tip:

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

        • The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.).

        • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.).

        • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

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    3. Adjust the valve clearance (exhaust side).

      Valve Clearance (cold)

      0.17 mm (0.00669 in.)

      Tip:

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

  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A286818C01
      V100135

      Seal Packing

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

      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.

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

    2. A294029N01

      Temporarily install the cylinder head cover sub-assembly with the 12 bolts.

    3. Fully tighten the 12 bolts in the order shown in the illustration.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

  19. INSTALL HARNESS BRACKET

    1. Install the harness bracket with the bolt.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. Connect the vacuum hose.

  20. INSTALL NO. 2 CYLINDER HEAD COVER

    1. A236904

      Install the No. 2 cylinder head cover.

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

    3. Install the 3 fuel pipe clamps.

  21. INSTALL SENSOR BRACKET

    1. Install the sensor bracket with the nut.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  22. INSTALL HARNESS BRACKET

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  23. INSTALL VENTILATION HOSE

    1. Install the ventilation hose and slide the 2 clips to secure it.

  24. INSTALL VACUUM PUMP ASSEMBLY

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  25. CONNECT ENGINE WIRE

    1. Connect the engine wire.

  26. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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  27. INSTALL REAR ENGINE UNDER COVER RH

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  28. INSTALL NO. 1 ENGINE UNDER COVER (for Half Cover Type)

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  29. INSTALL NO. 1 ENGINE UNDER COVER (for Full Cover Type)

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  30. INSTALL FRONT WHEEL RH

    103 N*m

    1050 kgf*cm

    76 ft.*lbf

  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    1. Connect the cable to the negative (-) battery terminal.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

      Note:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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