ENGINE MECHANICAL – VALVE CLEARANCE (HILUX/1KD–FTV, 2KD–FTV 14–5

(TASA MADE FOR ARGENTINA))

VALVE CLEARANCE (HILUX/1KD–FTV, 2KD–FTV (TASA

MADE FOR ARGENTINA))
1411J–10

ADJUSTMENT
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (–) battery terminal to pre-
vent airbag activation.
2. REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 14–24)
3. 2KD–FTV:
REMOVE ENGINE COVER BRACKET (See page 14–24)
4. 1KD–FTV:
REMOVE CHARGE AIR COOLER ASSY W/ INTAKE AIR CONNECTOR (See page 13–42)
5. 2KD–FTV:
REMOVE AIR CLEANER PIPE SUB–ASSY NO.2 (See page 14–24)
6. LOOSEN FUEL TANK CAP ASSY
7. REMOVE INJECTION PIPE (See page 11–14)
8. REMOVE CYLINDER HEAD COVER SUB–ASSY (See page 14–54)
9. REMOVE INJECTOR ASSY (See page 11–14)
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Align the matchmarks of the crankshaft pulley and timing
gear case cover by rotating the crankshaft clockwise.
HINT:
Make sure that both cam–noses (intake side and exhaust side)
of the cylinder No. 1 face upward.

Matchmark
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11. INSPECT VALVE CLEARANCE

EX EX EX EX (a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)
IN IN IN IN Write down valve clearance measurements that are out of the
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specified range. These measurements will be used later to de-
termine the size of the adjustment shim to be installed.
(b) Turn the crankshaft 360_ to set the No. 4 cylinder to TDC/
compression.

HILUX REPAIR MANUAL (Argentina) (DR201E)

14–6 ENGINE MECHANICAL – VALVE CLEARANCE (HILUX/1KD–FTV, 2KD–FTV
(TASA MADE FOR ARGENTINA))

(c) Check only the valves indicated.

EX EX EX EX (1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)
Write down valve clearance measurements that are out of the
IN IN IN IN specified range. These measurements will be used later to de-
A60175
termine the size of the adjustment shim to be installed.
12. ADJUST VALVE CLEARANCE
(a) Drain coolant (see page 16–3).
(b) Remove the fan shroud (see page 16–15).
(c) Remove the timing belt No. 1 cover (see page 14–44).
(d) Remove the timing belt (see page 14–44).
(e) Remove the camshaft timing pulley (see page 14–49).
(f) Remove the timing belt idler No. 1 (see page 14–44).
(g) Remove the timing belt No. 2 cover (see page 14–49).
(h) Remove the camshafts (see page 14–49).

(i) Remove the valve lifters.

(j) Using a micrometer, measure the thickness of the re-
moved lifter.
(k) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
A Thickness of new lifter
B Thickness of used lifter
C Measured valve clearance
A01082 Valve clearance (Cold):
Intake A = B + (C – 0.25 mm (0.0098 in.))
Exhaust A = B + (C – 0.40 mm (0.0158 in.))
(l) Select a new lifter with a thickness as close as possible
to the calculated values.
HINT:
Valve lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260
in.).
(m) Install the selected valve lifter.

HILUX REPAIR MANUAL (Argentina) (DR201E)

HILUX REPAIR MANUAL (Argentina) (DR201E)

Valve Lifter Selection Chart (Intake)

Installed lifter
thickness
mm (in.)
Measured
clearance mm (in.)

ENGINE MECHANICAL
–
(TASA MADE FOR ARGENTINA))
VALVE CLEARANCE (HILUX/1KD–FTV, 2KD–FTV
New Lifter Thickness mm (in.)
No. Thickness No. Thickness No. Thickness

Intake valve clearance (Cold):

0.20 to 0.30 mm (0.008 to 0.012 in.)
EXAMPLE:
A 5.250 mm (0.2067 in.) lifter is installed, and the
measured clearance is 0.400 mm (0.0158 in.).
Replace the 5.250 mm (0.2067 in.) shim with a new
No. 40 lifter.
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14–7
 14–8
HILUX REPAIR MANUAL (Argentina) (DR201E)

Valve Lifter Selection Chart (Exhaust)

Installed lifter
thickness
mm (in.)
Measured
clearance mm (in.)

ENGINE MECHANICAL
–
(TASA MADE FOR ARGENTINA))
VALVE CLEARANCE (HILUX/1KD–FTV, 2KD–FTV
New Lifter Thickness mm (in.)
No. Thickness No. Thickness No. Thickness

Exhaust valve clearance (Cold):

0.35 to 0.45 mm (0.014 to 0.018 in.)
EXAMPLE:
A 5.340 mm (0.2102 in.) lifter is installed, and the
measured clearance is 0.480 mm (0.0189 in.).
Replace the 5.340 mm (0.2102 in.) shim with a new
No. 42 lifter.
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 ENGINE MECHANICAL – VALVE CLEARANCE (HILUX/1KD–FTV, 2KD–FTV 14–9
(TASA MADE FOR ARGENTINA))

(n)
Install the camshaft and camshaft No. 2 (see page
14–49).
(o) Install the timing belt No. 2 cover (see page 14–49).
(p) Install the timing belt idler No. 1 (see page 14–44).
(q) Install the camshaft timing pulley (see page 14–49).
(r) Install the timing belt (see page 14–44).
(s) Install the timing belt No. 1 cover (see page 14–44).
(t) Install the fan shroud (see page 16–15).
(u) Add engine coolant (see page 16–3).
13. INSTALL INJECTOR ASSY (See page 11–14)
14. CHECK FOR FUEL LEAKS (See page 11–14)
15. INSTALL CYLINDER HEAD COVER SUB–ASSY (See page 14–54)
16. INSTALL INJECTION PIPE (See page 11–14)
17. 2KD–FTV:
INSTALL AIR CLEANER PIPE SUB–ASSY NO.2 (See page 14–24)
18. 1KD–FTV:
INSTALL CHARGE AIR COOLER ASSY W/ INTAKE AIR CONNECTOR (See page 13–42)
19. 2KD–FTV:
INSTALL ENGINE COVER BRACKET (See page 14–24)
20. INSTALL ENGINE COVER SUB–ASSY NO.1 (See page 14–24)
21. TIGHTEN FUEL TANK CAP ASSY
22. BLEED AIR FROM FUEL SYSTEM (See page 11–7)
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
24. CHECK FOR FUEL LEAKS
25. CHECK FOR OIL LEAKS

HILUX REPAIR MANUAL (Argentina) (DR201E)