Valve Clearance: Service and Repair
VALVE CLEARANCECOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V-BANK COVER SUB-ASSEMBLY
(a) Using a 5 mm socket hexagon wrench, remove the 3 nuts.
(b) Remove the V-bank cover.
4. REMOVE RADIATOR HOSE INLET
5. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/FRONT SUSPENSION BRACE UPPER CENTER)
6. REMOVE AIR CLEANER ASSEMBLY
7. REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the 2 VSV connectors.
(b) Remove the wire harness clamp.
(c) Disconnect the fuel vapor feed hose No. 1.
(d) Disconnect the fuel vapor feed hose No. 2.
(e) Disconnect the 2 vacuum hoses.
(f) Remove the clamp.
(g) Remove the 2 nuts and the emission control valve set.
8. REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the throttle motor connector.
(b) Disconnect the water by-pass hose No. 3.
(c) Disconnect the water by-pass hose No. 2.
(d) Disconnect the union to check valve hose.
(e) Disconnect the ventilation hose.
(f) Remove the 3 nuts and disconnect the pressure feed tube.
(g) Remove the 2 bolts and engine hanger No. 1.
(h) Remove the 2 bolts and surge tank stay No. 1.
(i) Remove the 2 bolts and surge tank stay No. 2.
(j) Using an 8 mm socket hexagon wrench, remove the 4 bolts.
(k) Remove the 2 nuts, emission control valve bracket and intake air surge tank.
(l) Remove the gasket from the intake air surge tank.
9. REMOVE IGNITION COIL ASSEMBLY
10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 2 engine wire harness clamps.
(b) Remove the 3 nuts and disconnect the engine wire harness.
(c) Remove the 9 bolts and cylinder head cover.
11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Using an E6 torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
(b) Remove the 9 bolts and cylinder head cover.
INSPECTION
1. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft pulley, and align the timing notch with timing mark 0 of the No. 1 timing belt cover.
(b) Check that the valve lifters on the No. 1 timing belt cover (IN and EX) are both loose.
If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
(c) Check the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve Clearance (Cold):
(2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.
(d) Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve Clearance (Cold):
(2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.
(e) Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve Clearance (Cold):
(2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.
INSTALLATION
1. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing the cylinder head cover.
(b) Install the cylinder head cover with the 9 bolts.
Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
(c) Install the engine wire harness with the 3 nuts.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
2. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing the cylinder head cover.
(b) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
(c) Using a "TORX" socket wrench, install the engine wire harness protector with the 2 bolts.
3. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
4. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
(c) Using an 8 mm socket hexagon wrench, tighten the 4 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
(d) Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
(e) Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
(f) Install the engine hanger No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
(g) Install the pressure feed tube with the 3 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
(h) Connect the ventilation hose.
(i) Connect the union to check valve hose.
(j) Connect the water by-pass hose No. 2.
(k) Connect the water by-pass hose No. 3.
(l) Connect the throttle motor connector.
5. INSTALL EMISSION CONTROL VALVE SET
(a) Install the valve set with the 2 nuts.
(b) Install the clamp.
(c) Connect the 2 vacuum hoses.
(d) Connect the fuel vapor feed hose No. 2.
(e) Connect the fuel vapor feed hose No. 1.
(f) Install the wire harness clamp.
(g) Connect the 2 VSV connectors.
6. INSTALL AIR CLEANER ASSEMBLY
7. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
8. INSTALL RADIATOR HOSE INLET
9. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Fit the 2 retainers and install the V-bank cover.
(b) Using a 5 mm socket hexagon wrench, tighten the 3 nuts.
Torque: 7.9 Nm (81 kgf-cm, 70 inch lbs.)
10. INSTALL FRONT FENDER APRON SEAL RH
11. ADD ENGINE COOLANT
12. CHECK FOR ENGINE COOLANT LEAKS