VALVE CLEARANCE > ADJUSTMENT

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

1. Disconnect the connector and 2 wire harness clamps.
   

   Text in Illustration 

   *1	Wire harness clamp
   *2	Clamp

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.
   

1. Remove the air cleaner filter element.
   

1. Remove the 3 bolts and the air cleaner case.
   

1. Remove the air cleaner hose.
   

1. Disengage the 3 claws and remove the engine cover.
   

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

2. Remove the 5 bolts and 2 nuts.
   

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

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

   Text in Illustration 

   *1	Protective Tape

1. Slide the clip and disconnect the 2 vacuum hoses.
   

2. Remove the 2 bolts and vacuum pump assembly.
   

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

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

2. Remove the 3 fuel pipe clamps.
   

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

4. Remove the No. 2 cylinder head cover.
   

1. Disconnect the vacuum hose.
   

2. Remove the bolt and wire harness bracket.
   

3. Remove the 12 bolts and the cylinder head cover.
   

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

   Text in Illustration 

   *1	Timing Mark
   *2	TDC Mark

   
   

   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.
      

      HINT:

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

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

   Text in Illustration 

   *1	No. 1 Exhaust
   *2	No. 2 Intake
   *3	Camshaft
   *4	Feeler Gauge

   
   

   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
      

      NOTICE:

      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
         
      1. Do not apply excessive force to the valve adjusting screw when using adjusting tools such as SST and a screwdriver.
         

      HINT:

      If the clearance is not as specified, record the out-of-specification measurement, 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.
   

   Text in Illustration 

   *1	No. 1 Intake
   *2	No. 3 Exhaust
   *3	Camshaft
   *4	Feeler Gauge

   
   

   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
      

      NOTICE:

      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
         
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.
         

      HINT:

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

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

   Text in Illustration 

   *1	No. 3 Intake
   *2	No. 4 Exhaust
   *3	Camshaft
   *4	Feeler Gauge

   
   

   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
      

      NOTICE:

      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
         
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.
         

      HINT:

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

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

   Text in Illustration 

   *1	No. 2 Exhaust
   *2	No. 4 Intake
   *3	Camshaft
   *4	Feeler Gauge

   
   

   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
      

      NOTICE:

      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
         
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.
         

      HINT:

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

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

   Text in Illustration 

   *1	Adjusting Screw
   *2	Lock Nut

   SST

   09248-56010  
   

2. Adjust valve clearance (intake side).
   

   Text in Illustration 

   *1	Adjusting Screw
   *2	Lock Nut
   *3	Feeler Gauge

   
   

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

      Text in Illustration 

      *1	Adjusting Screw
      *2	Lock Nut

      Torque:

      With SST:

      13 N*m{ 133 kgf*cm , 10 ft.*lbf }

      Without SST:

      20 N*m{ 204 kgf*cm , 15 ft.*lbf }

      HINT:

      1. 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).
         
      2. 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.)
   

   HINT:

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

1. 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
   

   NOTICE:

   1. Remove any oil from the contact surface.
      
   1. Install the cylinder head cover within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
      

2. 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. Install the wire harness bracket.
   

   Torque:

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

5. Connect the vacuum hose.
   

1. Install the No. 2 cylinder head cover.
   

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

3. Install the 3 fuel pipe clamps.
   

4. 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 }

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

2. 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. Install 2 new bolts onto the vacuum pump assembly.
   

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

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

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

2. 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 }

1. Engage the 3 claws and install the engine cover.
   

1. Install the air cleaner case with the 3 bolts.
   

   Torque:

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

1. Install the air cleaner filter element.
   

   NOTICE:

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

1. 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. Connect the air cleaner hose to the air cleaner cap.
   

   HINT:

   1. The clamp should contact the air cleaner hose stopper.
      
   2. Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.
      

1. Install the air cleaner hose.
   

   NOTICE:

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

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

Torque:

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