TOYOTA 3S-GE, 3S-GTE, 5S-FE ENGINE REPAIR MANUALTOYOTA 3S-GE, 3S-GTE, 5S-FE ENGINE REPAIR MANUAL INTRODUCTION MIX ENGINE MECHANICAL [Ql TURBOCHARGER SYSTEM EFISYSTEM Gl COOLING SYSTEM LUBRICATION SYSTEM IGNITION SYSTEM [GH STARTING SYSTEM CHARGING SYSTEM SERVICE SPECIFICATIONS JME STANDARD BOLT TORQUE SPECIFICATIONS [ICE SST AND SSM © 2002 TOYOTA MOTOR CORPORATION Al rights reserved. This book may not be re- produced or copied. in whole or in part, with: ut the written permission of Toyots Motor Nov. 14, 1989 07-891114.00, 9: Mar 14, 2002 17-020313-01-3,INTRODUCTION HOW TO USE THIS MANUAL IDENTIFICATION INFORMATION GENERAL REPAIR INSTRUCTIONS PRECAUTIONS FOR VEHICLES EQUIPPED WITH ACATALYTIC CONVERTER ABBREVIATIONS USED IN THIS MANUAL ........ IN-4 Page IN-2 IN-4 IN-6 IN-7IN-2 INTRODUCTION — How to Use This Manva HOW TO USE THIS MANUAL To assist you in finding your way throug :~1s manual, the Sec- tion Title and major heading are given at t~e :o0 of every page. An INDEX is provided on the 1st page of each section to guide you to the item to be repaired At the beginning of each section, PRECAUTIONS are given that pertain to all repair operations contained in that section. Read these precautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy col- umn to quickly lead you to the solution, REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: | RH Camshaft | A camsnatt Li Camshaft Timing Pulley Timing Pulley Timing Belt | Gasket Timing Belt Tensioner Reet aren Belt Cover T i 600 (43, 58) #420 (30, 41) C = Oil Pump SF No.2 Idler Pulley Pulley Crankshaft Timing Pulley Py Timing Belt Guide oa eae . ese ens [kocem (itib, Wind]: Specitied torque + Precoated part # For use with SSTINTRODUCTION — How to Use This Manual IN-3 The procedures are presented in a step-by-step format: © The illustration shows what to do and where to do it. © The task heading tells what to do. © The detailed text tells how to perform the task and gives other information such as specifications and warnings, Example: Task heading: what to do 6. INSTALL CRANKSHAFT PULLEY (a) Using SST, install the bolt. SST 09213-54015 (90119-08126) Mustravion what to vs and where Set part No. Comiponent part No. Detail text: how to do it (b) Install the bolt. «~~ Torque: 1,100 kg-cm (80 ft-lb, 108 Nm) Specitication This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at @ glance and only when necessary, the text below it provides detailed information. Important specifications and warnings always stand out in bold type REFERENCES References have been kept to @ minimum. However, when they are required, you are given the page to go to SPECIFICATIONS Specifications are presented in bold type throughout the text in the applicable step. You never have to leave the procedure to look up your specifications. All specifications are also found in Appendix A, speciications, for quick reference. CAUTIONS, NOTICES, HINTS: ‘© CAUTIONS are presented in bold type, and indicate there is a Possibility of injury to you or other people. © NOTICES are also presented in bold type, and indicate the Possibility of damage to the components being repaired. © HINTS are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair.IN-4 INTRODUCTION — Identification Information, General Reps ~ Cy OP Seal Lock Adhesive | scrctions. IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped or = cylinder block. ear side of the GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in order to facilitate reassembly. 3. Observe the following: (a) Before performing electrical work, disconnect the negative (-) cable from the battery terminal. (b)_ If itis necessary to disconnect the battery for inspec- tion or repair, always disconnect the cable from the negative (—) terminal which is grounded to the vehi: cle body, ()_ To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it (a) Clean the battery terminal posts and cable terminals with a shop rag. Do not scrape them with a file or other abrasive object. (e} Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do ot use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is pro- perly in place 4. Check hose and wiring connectors to make sure that they are secure and correct. 5. _Non-reusable parts (a) Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones. (b)Non-reusable parts are indicated in the component illustrations by the “#"” symbol, 6. Precoated Parts Precoated parts are the bolts, nuts, etc. which are coated with a seal lock adhesive at the factory. (2) Ifa precoated partis retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.INTRODUCTION — General Repair Instructions IN-5 {b) Recoating of Precoated Parts (1) Clean off the old adhesive from the part's threads. (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the part's threads. (c)_ Precoated parts are indicated in the component illustrations by the “*” symbol, 7. When necessary, use a sealer on gaskets to prevent leaks. 8. Carefully observe all specifications for bolt torques. Always use a torque wrench. 9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found at the back of this manual 10. When replacing fuses, be sure the new fuse is the correct amperage. DO NOT exceed the fuse amp rating or use one of a lower rating 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (2) {If the vehicle is to be jacked up only at the front or rear end, be sure to chock the wheels in order to ensure safety. (b) After the vehicie is jacked un, be sure to support it on stands, It is extremely dangerous to do any work on the vehicle raised on a jack alone, even for a small job that can be finished quickly 12. Observe the fotiowing precautions to avoid damaging the parts: (a} Do not open the cover or the case of the ECU unless. absoutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (c)_ When disconnecting vacuum hoses, pull on the end of the hose, not the middle. (¢) When separating electrical connectors, pull on the connector itself, pot the wires.General Repair instructions, Prece. IN-6 INTRODUCTION — Vehicles Equipped with a Catalytic (e) When steam cleaning an e-cine, protect the distribu- tor, coil air filter, and VSV om water. (f1 Never use an impact wrench :c remove or install temp. switches or temp. sensors {g) When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. (h) When using @ vacuum gauge, never force the hose onto a connector that is too large. Use 2 step-down adapter instead, Once the hose has been stretched, it may leak. Example | 13. Tag hoses before disconnecting them: a) (2) When disconnecting vacuum hoses, use tags to iden- WIV for tify how they should be reconnected. Whe wwe PY fb) After completing a job, double check that the | vacuum hoses are properly connected. A label under > the hood shows the proper layout. Lenin Bet Soe PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard, To prevent this, observe the following pre- cautions and expiain them to your customer. 1. Use only unleaded gasoline. 2. Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes, 3. Avoid spark jump test. (2) Perform spark jump test only when absoulutely necessary and as quickly as possible (0) Whi festing, never race the engine. 4. Avoid prolonged engine compression measurement. Engine compression tests must be made 2s quickly as possible. 5. Do not run engine when fuel tank is neary empty. This may cause the engine to misfire and create an extra load on the converter. 6. Avoid coasting with ignition turned off and prolonged braking. 7. Do not dispose of used catalyst along with parts con- tamimated with gasoline or oil.INTRODUCTION — Abbreviations Used in This Manual IN-7 ABBREVIATIONS USED IN THIS MANUAL Alc. ACIS Approx. AT BTDC BvsV ECU ECT EFI EGR ESA EVAP x Ex. FIPG FL FPU IG IN Isc LH LHD MP. MIT 0D, 0/0 os PCV Ps RH RHD SSM ssT STD sw Tecs TDC Tus Twe u/s vsv viv wi wio Air Conditioner Acoustic Control Induction System Approximately ‘Automatic Transaxle Bottom Dead Center Bimetal Vacuum Switching Valve Electronic Controlled Unit Electronic Controlled Transaxle Electronic Fuel Injection Exhaust Gas Recirculation Electronic Spark Advance Evaporative (Emission Control) Exhaust (Manifold, Valve) Except Formed in Piace Gasket Fusible Link Fuel Pressure Up. Ignition Intake (Manifold, Valve) Idle Speed Control Left-hand Left-hand Drive Multipurpose Manual Transaxle Overdrive Oversized Positive Crankcase Ventilation Power Steering Right-hand Right-hand Drive Special Service Materials Special Service Tools Standard Switch TOYOTA Computer Controlled System Top Dead Center TOYOTA-Variable Induction System Three-Way Catalyst Undersize Vacuum Switching Valve Vacuum Transmitting Valve With WithoutENGINE MECHANICAL DESCRIPTION (5S-FE) DESCRIPTION (3S-GE and 3S-GTE) TROUBLESHOOTING ENGINE TUNE-UP .. ACOUSTIC CONTROL INDUCTION SYSTEM (acis) TOYOTA-VARIABLE INDUCSTION SYSTEM (T-vIs) IDLE HC/CO CONCENTRATION CHECK METHOD (w/TWC) IDLE CO CONCENTRATION CHECK AND ADJUSTMENT METHOD (w/o TWC) COMPRESSION CHECK .. TIMING BELT (5S-FE) .... TIMING BELT (3S-GE and 3S-GTE) CYLINDER HEAD (5S-FE) CYLINDER HEAD (38-GE and 38-GTE) CYLINDER BLOCK (5S-FE) ...... on CYLINDER BLOCK (3S-GE and 3S-GTE) EM-1 Page EM-2 EM-4 —M-7 EM-11 wo GM EM-26 —M-27 EM-29 —M-31 EM-33 EM-45 EM-64 EM-98 . EM-148 . E174EM-2 ENGINE MECHANICAL — Description (5S-F= DESCRIPTION (5S-FE) The 5S-FE engine is an in-line, 4-cylinder, 2.2 liter DOHC 16-valve engine.ENGINE MECHANICAL — Description (6S-FE) EM-3 ‘The 5S-FE engine is an in-line, 4 cylinder engine with the cylinders numbered 1 - 2 - 3 ~ 4 from the front. The crankshaft is supported by 5 bearings inside the crankcase. These bearings are made of aluminum alloy. The crankshaft is integrated with 8 weights for balance. Oil holes are placed in the center of the crankshaft to supply oil to the connecting rods. bearing, pistons and other components. The ignition order is 1 - 3 - 4 ~ 2. The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and with pent-roof type combustion chambers. The spark plugs are located in the center of the combustion chambers. The intake manifold has 4 independent long ports and utilizes the inertial super-cherging effect to improve engine torque at low anc medium speeds. Exhaust and intake vaives are equipped with irregular pitch springs made of special valve spring carbon steel which are capable of functioning no matter what the engine speed, The intake camshaft 's driven by a timing belt, and a gear on the exhaust camshaft engages with a gear on the exhaust camshaft to drive it. The cam journal is supported at 5 places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and gears is accomplished by oil supplied through the oiler port in the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type system, in which valve adjusting shims are located above the valve lifters. This permits replacement of the shims without removal of the camshatts, Pistons are made of high temperature-resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the valves. Piston pins are the full-floating type, with the pins fastened to the neither the piston boss nor connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No.1 compression ring is made of steel and the No.2. compression ring is made of cast iron. The oil ring is made of a combination of steel and stainless steel. The outer diameter of each piston ring is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls when they are mounted on the piston. Compression rings No.1 and No.2 work to prevent gas leakage from the cylinder and an oil ring works to clear oil off the cylinder walls to prevent it from entering the combustion chambers. The cylinder block is made of cast iron. It has 4 cylinders which are approximately twice the length of the piston stroke, The top of the cylinders are closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders. The oil pan is bolted onto the bottom of the cylinder block. The oil pan is an oil reservoir made of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the bottom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and thus shifting the oil away from the oil pump suction pipe.EM-4 ENGINE MECHANICAL — Description (3S-GE anc DESCRIPTION (3S-GE and 3S-GTE) The 38-GE and 3S-GTE engines are an in-line, 4-cylinder, 2.0 liter DOHC 16-valve enare 38-GEENGINE MECHANICAL — Description (3S-GE and 3S-GTE) beEM-6 ENGINE MECHANICAL — Description (3S-GE and 3S-¢ The 3S-GE and 3S-GTE engines are an in-line, 4 cylinder engine with the cylinaers numbered 1 - 2-3 - 4 from the front. The crankshaft is supported by 5 bearings inside the crankcase. T~ese Dearings are made of aluminum alloy. The crankshaft is integrated with 8 weights for balance. Oil holes are placed in the ce to supply oil to the connecting rods, bearing, pistons and other components. The ignition order is 1 ~ 3 ~ 4 ~ 2. The cylinder head is made of aluminum alloy, with 2 zross flow type intake and exhaust layout and with pent-roof type combustion chambers. The spark plugs are ioceted in the center of the combustion chambers. The intake manifold has 4 (3S-GE) or 8 (3S-GTE) independent long ports and utilizes the inertial super- charging effect to improve engine torque at low and medium speeds. Both the intake camshaft and the exhaust camshaft are driven by a single timing belt. The cam journal is supported at 5 places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and cam is accomplished by oil supplied through the giler portin the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type system, in which valve adjusting shims are located above the valve lifters. This permits replacement of the shims without removal of the camshafts. Pistons are made of high temperature-resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the valves Piston pins are the full-floating type, with the pins fastened to the neither the piston boss nor connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No.1 compression ring is made of steel and the No.2 compression ring is made of cast iron. The oil sing is made of a combination of steel and stainless steel. The outer diameter of each piston ring is slightly larger ‘than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls when they are mounted on the piston. Compression rings No.1 and No.2 work to prevent gas leakage from the cylinder and an oil ring works to clear oil off the cylinder walls to prevent it from entering the combustion chambers. 1e" of the crankshaft The cylinder block is made of cast iron, It has 4 cylinders which are approximately twice the length of the piston stroke, The top of the cylinders are closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders. The oil pan is bolted onto the bottom of the cylinder block. The oil pan is an oil reservoir made of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the bottom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and thus shifting the oil away from the oil pump suction pipe,ENGINE MECHANICAL — Troubleshooting —M-7 TROUBLESHOOTING ENGINE OVERHEATING Fabien Posie eause Remedy roe | | Engine overheats Coorg system fauly Troubleshoot cooing sstom | 0-8 | | Incorrect ignition timing Reset timing j HARD STARTING Problem Possible cause ] Remedy Page Engine wil not ck Staring stom fly Troubleshoot aire system | 87-2 tGonts 5 atu no working 2 Fam hterogged & Feat ine clogged or ating EF system probleme Roost as mecssny gitar prolome Perr spk et 6s 2 te | 2 Better Spark faulty nape igs ere igriesin cots disconect or oten | Ispet cords ies Vaca eae Hepat 0 necessary orev ine | 5 EGK tte es-Fe and 98-070 © Air intake chamber (3S-GE} | 3 Aas one BS.Ge 2 Aine asere Tiree boy 3 Cue # Ste booster te | } throttle body Low compression check competion ena ROUGH IDLING Probe Persie co — ove Rough ie, tis | Spam pg foul 1 epeet ngs vere © Distributor | Inspect distributor | iG-11 | incor ton ting Resetting | eyw2a, 23 2 Gn ne 6548 ars as.cre & fnate mon |EM-8. ENGINE MECHANICAL — Troubleshooting ROUGH IDLING (Cont'd) Problem le cause Remedy Page Rough idle, stalls or © Air intake chamber (3S-GE) | misses (Cont'd) @ ACIS vaive (3S-GE) © T-VIS vaive (38-GTE) © Throttle body © ISC valve 1 Broke booster ine | Ar suction between airflow meter and | throttle body | Incorrect idle speed Check IC system aLN74, 176, 178 | incorrect valve clearance Adjust vate clearance eM-13,17 | EFI system problems | Repair as necessary | Engine overheats | Check cooling system lcos | Low compression | Check compression eM-31 ENGINE HESITATES/POOR ACCELERATION Problem Possible cause ered ree Engine hesitates Spark plug faulty Inspect plugs _ oor acceleration High-tension cord faulty Inspect cords Io-6 Vacuum leaks Repair as necessary | | @ PCV line @ EGR line (5S-FE end 38-GTE) | intake man‘or ° osevae & rake sooste ne | Ar suction between ar ow meter Repair as necessary and tno bey Ince ignition timing Resetting v.22, 23 Inconectvahe clsrance Adjust vabe clsrance aats3.17 Fuel system clogged hack ful system A cleaner clogged Chacha leaner jews EF sytem problems Reps a8 necessary | Emission contol system problem | (Cts engin © EGR system ahways on check E98 system | (SS-FE and 3S-GTE) Engine overheats Check cooling system feos | Low compression | Check compression 3sENGINE MECHANICAL — Troubleshooting EM-9 ENGINE DIESELING Problem Peslble cause Remedy rove Engine diesels | EFI system problems Repair as necessary | (runs after ignition Incorrect ignition timing Reset timing EM-22, 23 soit is tuned of EGR aytem foul (SS-FE and 26-GTEI | Check EGR ystems AFTER FIRE, BACKFIRE Problem Possible cause Remedy age Mutt exporon _Decnaton fel cut eytem always off| Check EFI uel eu system ter elon deceleration oly | Mutter exposion Ai cleanercloggee Check scene Towers ter real the gaye problem Resi a8 necessory me | Incorrect ignition timing Reset timing EM-22, 23 Engine backfires | _EFI system problem | Repair as necessary | Vac ea Chick hoses an apa as Pe ne necessary ® EGR ne 65-FE and 26-678) © intake mantot * Air itke chamber (98-CE1 '® ACIS valve (3S-GE) # Tvs aie 86-670 | Trott body # isc vane Brake booster ine Acsucton betwen a flow meter | RepoW as necessary and tote body Insufent ful fw | rroubuhoot uel aystem | FL12 inorct gion tning Reset timing ew.72,29 Incomes ve clorance Adjust va oarance eawr3.17 Carton caposits my combustion chambers| inept ender hea 276.118 EXCESSIVE OIL CONSUMPTION Problem Possble cause Remedy Poe Excessive oil Oil leak Repair as necessary | consumption PCV line clogged Check PCV system Piston sng worn or damaged Check rns ev60 186 Valve stm and guide busing worn | Check vt Valve stem oil seal worn 3nd guide bushing) EM-77, 119} Check seals.EM-10 ENGINE MECHANICAL — Troubleshooting EXCESSIVE FUEL CONSUMPTION Vacuum leaks © PCV ine. Air intake chamoer 35-GE! ACIS valve 3S-GE) T.VIS vaive |3-GTE) Throttle boy ISC vaive © Brake booster line EFI system problems Repair as necessary Repair as necessary Problem Possible cause | Remedy Page | Poor gasoline Fuel leak | Repair a8 necessary mileage Air cleaner clogged | Check air cleaner eM.11 Incorrect ignition ining Reset timing em.22, 29] EF system problems Repair as necessary @ injector foulty Deceleration fuel ct system fouty Idle speed too high Check ISC system 3174, 176| | "78 | Spark plug faulty Inspect plugs 16-6 EGR system always on Check EGR system (38-FE ond 38.GTE) | Low compression Check compression emt Ties improper inflated Inflts tes t proper pressure Clutch sips Troubleshoot clutch | Brakes drag Troubleshoot brakes UNPLEASANT ODOR Problem Possible couse ] Remedy Paoe Unpleasant odor Incorrect idle spec Creek ISC system 174, 176| 178 Incorrect ignitor ming Reset timing ew.22, 29ENGINE MECHANICAL — Engine Tune-Up EM-11 ENGINE TUNE-UP INSPECTION OF ENGINE COOLANT (See steps 1 and 2 on page CO-6) INSPECTION OF ENGINE OIL (See steps 1 and 2 on page LU-6) INSPECTION OF BATTERY (See steps 1 and 2 on page CH-3) Standard speci 1.25 — 1.27 when fully charged at 20°C (68°F) INSPECTION OF AIR FILTER 1. INSPECT AIR FILTER Visually check that the element is not excessively dirty, damage or oily. 2. CLEAN AIR FILTER Clean the element with compressed air. First blow air from the inside thoroughly. Then blow off Outside fees the outside of the element. INSPECTION OF HIGH-TENSION CORDS (See page IG-6) Maximum resistance: 26 k per cord INSPECTION AND ADJUSTMENT OF SPARK PLUGS (Conventional Type only) (See page IG-7) SS-FE Correct electrode gap: 1.1 mm (0.043 in.) Recommended spark plugs: ND K16R-U11 NGK BKRSEYA11 3S-GE Correct eletrode gap: Recommended spark plugs: ND K20R-U NGK BKRG6EYAEM-12 ENGINE MECHANICAL Engine Tune-Up. INSPECTION AND ADJUSTMENT OF ALTERNATOR DRIVE BELT (5S-FE) (See step 3 on page CH-3) w/ A/C New belt 6-9 mm (0.24 ~ 0.36 in.) Used belt 9— 11 mm (0.35 — 0.43 in.) w/o A/C New belt 11-15 mm (0.43 — 0.59 in.) Used belt. 13 - 17 mm (0.51 — 0.67 in) Drive belt tension (Reference): w/A/C New belt 70 ~ 80 kg Used belt 45 - 55 kg wio AIC New belt 45 ~ 55 kg Used belt 20 - 35 kg INSPECTION AND ADJUSTMENT OF ALTERNATOR DRIVE BELT (3S-GE AND 3S-GTE) (See step 3 on page CH-3) Drive belt deflection: w/ A/C New belt 9~ 11. mm (0.35 ~ 0.43 in.) Used belt. 13 ~ 16 mm (0.51 - 0.63 in) w/o AIG New belt 11~— 14mm (0.43 ~ 0.55 in) Used belt 12-18 mm (0.47 - 0.71 in) Drive belt tension (Reference) w/ A/C New belt 70 ~ 80 kg Used belt 30 - 45 kg w/o AIC New belt 47-72 kg Used belt 36 - 52 kgENGINE MECHANICAL — Engine Tune-Up EM-13 = a INSPECTION AND ADJUSTMENT OF VALVE CLEARANCE (5S-FE) HINT: Inspect and adjust the valve clearance when the engine is cold. 1, DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS 2. REMOVE CYLINDER HEAD COVER (See step 22 on page EM-70) 3. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with timing mark ‘“O" of the No.1 timing belt cover. (b) Check that the valve lifters on the No.1 cylinder are loose and valve lifters on No.4 are tight. If not, turn the crankshaft one revolution (360°) and align the mark as above. 4. INSPECT VALVE CLEARANCE (a) Check only those valves indicated. © Using a feeler gauge, measure the clearance bet- ween the valve lifter and camshaft © Record the specicifications of the valve clearance measurements. They will be used later to deter- mine the required replacement adjusting shim, Valve clearance (Coldh: Intake 0.19 — 0.29 mm (0,007 — 0.011 in) Exhaust 0.28 — 0.38 mm (0.011 — 0.015 in.) (b) Turn the crankshaft one revolution (360°) and align the mark as above. (See procedure step 3) () Check only the valves indicated as shown. Measure the valve clearance. (See procedure step (al) 5. ADJUST VALVE CLEARANCE (2) Remove the adjusting shim. ‘© Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. © Using SST (A), press down the valve lifter and place SST (8) between the camshaft and valve lifter. Remove SST (A) SST 09248-55010 HINT: Before pressing down the valve lifter, position its notch toward the spark plug side.EM-14 ENGINE MECHANICAL — Engine Tune-Up. @ Remove the adjusting shim with a small screwdriver and magnetic finger () Determine the replacement adjusting shim size by following the Formula or Charts: '® Using a micrometer, measure the thickness of the removal shim. © Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T ..... Thickness of used shim A ..... Measured valve clearance N...... Thickness of new shim Intake N= T + (A — 0.24 mm (0.009 in.)) Exhaust N= T+ (A — 0.33 mm (0.013 in.)) © Select a new shim with a thickness as close as possible to the calculated valve. HINT: Shims are available in seventeen sizes of 0.05 mm (0.0020 in), from 2.60 mm (0.0984 in) to 330 mm (0.1299 in) (c)__ Install a new adjusting shim, © Place a new adjusting shim on the valve lifter. © Using SST (Ai, press down the valve lifter and remove SST (6). SST 09248-55010 (d) Recheck the valve clearance. REINSTALL CYLINDER HEAD COVER (See step 7 on page EM-92) RECONNECT HIGH-TENSION CORDS TO SPARK PLUGSENGINE MECHANICAL — Engine Tune-up EM-15 Adjusting Shim Selection Using Chart INTAKE Measured clearance (mm) Tae a eeeegaeesesceegesgegesesesegage esseeeage Wl diiclichel al cl cdjad:el ed vl el cu elieuled ied ese, 55 oS esos od GSles oo 3) 0000-0105 33] 3.080 72 03 020204044606 Oe G5 0808 10 1011012 Taio tala Ta Te 1 6 16 16,18 16:20 20100 00 24 0404 6 050605 8 08 1010-10 127211211414 14 16 16 16 18 18 18 20°20 20,20122/4 28 040406 061050808081 10, 1011 ‘1214114114 16 16 16.18 18.18.20 20 20122 22122'24(26| ["01076=0,100_| "020202" c2 02408 [od 50g 008 Y0:10,10"12 2112141414 1616 1618-18 18 20[20 20/22/22 20 24 24 26 28 (0,101-0.125 | 02 02 C2 02 06 04046 6506 008101010 7212121414 14161616 1181620 20 20,20 2217004 244,28 24] (0:126-0.150 | 02-0204 O# 0 005 0080810101072 122[14 141416 1616 1818 1820 2120.22 22122 24,24 2426 2628 0] ["0.151-0.175_ | 02 02 04 C4 G4 06 06106 08 08! 0g 10'10/10'12/12112\14 14 14:16 16 16]18_18 18 20 20|20 22 22|22'24 24 24 26 2626126 30, 176-0.189_| 0 0 5 0506 008 T1010 01214144 4 16.15.18 1818.18 20 22 222 224 24 26 262628 2830 22 0190-0.290 [0301-01325 0.326-0.350_| (0.351-0.375| (0376-0. [o.401-0.495 IaH M_ MERVVVOLOMNNTI RET RADA DM DINs SARA DNBOe a (og 08-1010 10 1242 12.4 14141616 16 18 18 18,20 201202022 2224 24 242625 26 29.28 28,3090 90,3192 2) (06 06 10-10-12"12(12/14 14/14 16,16 16 1618 18:20:20 20:20 20:22 24/24 24 26/26 26 28 28 28 30 30 30,32 32|22 34 34 0 8 10121212 1414146161618 18 18 20 20 20 20202024 24246 2626 282628 3.303092 2 31 a [1012 12 14 1414/3616 16 1816/16 20,20 20 20\20|22[24/24|24]26 26 2628128 28 30 30.30 32 32.32 34 34 34 34 [8 10 12-14 14 14 16 16 16,1818 18 20,20(20,22|20{20 24[24'24'26 25,26 28 26 28 40 30 30 32-32 32.44 34 34 3 476-0500, 10426-0450 |10-12 14-1416 1616/1818 18,20 2012020 2022 2424 26 26 2528 28783090 30 32°30 32-94 3436 3 (0.451-0.475_|10 12 14 16 16 16 18 18 1820 20|20,22122 2924/24 24/2626 26 28 28/2890, 30,30 2-14-16 16 18 18 18,20 20120,22 22 20/24 241782626 26 012828 9) 150,80 2.03434 3 [0.501-0.595 [12.14 16 18 18 18 20 20 20 22120 22\ 24/24 24 26 26 26 28 28128 30 90] 30,321 32/32'34134|34 38] 0.526-0.550) 0551-0575 [14116 18 18 20 20/20 22/22 22124 24 24 26 26 26 28 28178 30 30 90,321 32132|34 34 3434 14 16-18 20 20/20 22.22.22 24,24 24 26 26 26,2828 28 30 30:30 2) -0.576-0.600 | [o.r51-0.775 1618-2020 72 20207424 24 26,26 26 282828 90 90,30 2 2213 ).676-0.700 {20,22 24 24 26 26,26 28) 20,221 24 26 26 26128 2 (22/24 26 26 28128128 20 122 2426 28 28/28|30/90,30 32 (0.776-0.800 | (0.826-11850 (0.851-0875 (0876-0.900 [oiso1-0.925' 0.926-0.950 4 26 28 28 30 30130 32:32 30 34 34 34 3, BO1=0.825 [24 26|28 30 30 20/32 32 32.34 34 34 34) 34 New shim thickness mm (in) Shir T Shim No. No. Thickness Thickness (0.951-0.975, (0.976-1.000 1.001=1.025 02 250 10.0984) 20 | 2.95 (0.1161) 04 265 (0.1008), 22 | 3.00 (0.1181) 6-1 06 2,60 (0,1024)| 24 | 3.05 10.1201) 2.65 (0.1043)| 26 | 3.10 (0.1220) 0 _ 2.70 (0.1083) 3.15 (0.1240) [122.75 (0,1083)| 30 _| 3.20 (0.1260) 14 | 2.80 10.1102)| 32 | 3.25 (0.1280) 6 | 285 (0.1122)| 34 | 3.30 (0.1289) (ta | 2.90 (0.1142) 2 Intake vaive clearance (Cold): 0.19 - 0.29 mm (0.007 — 0.011 in} EXAMPLE: The 2.800 mm (0.1102 in) shim is installed and the measured clearance is 0.450 mm (0.0177 in). Replace the 2.800 mm (0.1102 in) shim with a No.22 shim.EM-16 ENGINE MECHANICAL — Engine Tune-Up Adjusting Shim Selection Using Chart EXHAUST Measured inataled shim Thiginess TRA : 1 clearance (SISSSSSSSSSSSSSSSSESSSSSSSSSSSESSSS RS sss mm)” ose ee Seek = SReSeS SESS SSS SSSSSSEESERESESE 0.000-0.025 { (02 02102|02/02 04] 04 04 06 06 06 06108 08/10/10) 10/12/12] 12.14 14 14 16 16 16 18 20.29) 0026-0050. [ || {02/0202 coos 06 08-08 10-10'12"12 1212.14 14 16 16-16 16-18 182020 cei {065 0505-08 O8-1010-1012'1212 14 tal 1416.16 16-1818 1820 2074 1 702/02!02 02'02|02|04/04 06 06156 06,08 08 10 10 10 10 12112/14|14/14114 ‘18 18 18 18 20 20 22 24] | Jo2/02.02[02 02 04/04/04 06 06[06[08 08|08 10 10 10 12 12 12 14/14|14/16|16|16 18 18 18 20 20 20 22 24 26. {0210202 02102 otf aos 08 0 80810110 12 12-12 1214 1416 16,1616 18 18/20 20 20 20 22-20 24 26, (2/02 [022 0204 406065 0088 10" Y0|10 1212-12 1414 14 16 16 16 18 18 18/20:20,20 20 22-22 2426-26, {2020202024040 06,06 06,05] Oe 10 10'10,T0l1212 14 14 14 14 16-16 18 18 18 18:20:20.22 22-22 22 24 24 26-78. (02{02[02 [0404 0406 06 06 08,08 08 10,10-10/12/12,12 14-14 1416 16 16 18 18 18 20:20:20 22 22122 24 2 24 26 28 20| [102/02 04/04/04'04:06.06 08 08 08 08 10 10/12'12!12/12/14)14116 16 16 16 18 18 20)20]20120122 22 24/24.24 24 26 26 28 30 6 28 8 2 (0.251-0.275 | 102/04(04/04 06 06 08 08 0606-10 10-10-12 12 12'14/14]14|16 16 16 16 18 18 20 20/20122/221z2 24/24|24]26 26 26 28 30 32, 11275-0278 | 024005, 06 5 8 0501010 012 12 121414141616 16.18.1818 2020 20-2 22,2024 24 (.280-0.380, | | 0,381-0.400 [04 06106|10110.1010 12 12 14 14 14 14 16 16 18 18 18 18.20.20 22 22122 22 24 24 26 26,2626 2826130, 30/30 30, 0401=0.425 06108 10/10"10'12'12 1214 14 14-16 16 16 1 16 18 20 20 20 20122122124 24/24 26 26:26 2 28,28 90 30 30:32:32 (1426-0450 (6108]10/1212 12 1214 14 1616 1616 18 18-20 20.20 20 20'20 24°24 24 24|26 26 28 28 28 28 90/30 3292 02 2: (0.451=0.475 (08|10/12[12'12 14 14 14 16 16 16 18 18 18 20 20 20 20 20 20 24 24 24 26/26'26 28 28 28 90 90100 22132192 34194 (0476-0.500 [0810-12 1414 1414 16 16 18 18.18 1820 20 20 20 22 22-24 24 26 26 26 26 28-26 90:90 30 30:92 92 3434.34 (501-0.525 [1012-14 14 14 16 16 16 18 18 18-20-20 20 22 20 20 2424-24 26 26 2628 28 28 90 30:30 32 92/92 94 34 3434] [0.526-0.550 [10 12 14 16 16 16 16 18 18 20 20 20 20 22 22 24 24 24 24 26 26 28 28 28 28 30 30 92 32.32 32134 34134) O.551-0.575 12 14 16 16.16 18 16 18 20 20 20 22122 22 24 24 24 26 26 26 28 28,28 90.90.90 92 32 32M 34 94 34 (.576-0.600 12 1416 18 18 18 1820 20 22 22 20 20 24 24 26 26 26 26 28 28 30 90.90 20-92 92 M 24.34 34/34] {TOU601=0.605 [14°16 18 18 18 2) 20 20°22 22120 24124 24 26 26 26 28 28.28 30 30 90 232.92 4 34 O43 18-18 20 20 20 20 22 2024/24 2424] 26/2628 26 28 28 90 30 22 3232 32.4 3 16-18 20 20 20 22-22'20|4 24 2426 26 26 2828 28 20 30, ao) ‘2828 30/90|30 30 32 32 34 34 94 34 34] 16-18 20 22 22122,20 24 24 26:26 26 26 22222024 24 24 26 26 26128 28 28130 30 30'32 32 32/34 34 34 34 (0,726-0.750 [1820 2224/24/24 24'26 26 2828128 28 30/90/92 32.32.32. 4 3 (0.751-0.775 [20122 24/24/24 26 26 26|28 28 28 30 30/30/32 32132134 34 34 34] 26 26 26.28 28-30 32) elias 3 3 3 (0,776-0.800 [2022 2426126 266 28/28 30 30 80 303032 34 94 34 34 34] ‘0.801=0.825- [22/24/26 2626 2828 28 30 90/90,32 32/32 94 34 34 34 10,826-0,850_{22'24|26 26] 2828/28/30 90) 3232/32) 32134124) 34] 70.851=0.875 24/28/28 28 28 90 30,30,32 30 30138 34 3434 [e4 26128 20/20 30 20132 29 34/4 34 3434] ‘0,901-0.925 [26/28 30|30 30/32 321 92/34/34) 34134] [Shim Shim (0,926-0.950 [26 28/30 32 321323134343) No ns (1951-0.975 [28 30/32 32/92 34 34 344] (02 2.580 (0.0984)| 20 | 2.95 (0.1161) [-o.a76-1,000_ [2830/3234 34134 34 34 ee eae 04 | 285 (0.1004)| 22 [3.00 (0.1181) eee eae 06 | 2.6010.1024)| 24 | 3.08 (0.1201) 08 | 2.65 (0.1083)! 26 | 3.10 (0.1220) 10 | 2.70 (0.1063)) 28 | 3.18 10.1240) | 12 | 2.75 (0.1083)| 30 | 3.20 (0.1260) 14 [2.80 (0.1102)| 32 | 3.25 10.1280) | 16 | 2.86 (0.1122) 34 | 330 (0.1299) 18 | 2.90 (0.1142) | New shim thickness __mm (in) Thickness ‘Thickness Exhaust valve clearance (Cold): 0.28 — 0.38 mm (0.011 — 0.015 in} EXAMPLE: The 2.800 mm (0.1102 in) shim is installed and the measured clearance is 0.450 mm (0.0177 in). Replace the 2.800 mm (0.1102 in) shim with a No.18 shim.