Engine tune-up¶

Inspection of engine coolant¶

(See steps 1 and 2 on page CO-4)

Inspection of engine oil¶

(See steps 1 and 2 on page LU-6)

Inspection of battery¶

(See On-vehicle inspection, steps 1, 2)

Standard specific gravity: 1.25 – 1.27 when fully charged at 20°C (68°F)

Inspection of air filter¶

(See Maintenance operations)

Inspection of high-tension cords¶

(See On-vehicle inspection (3S-GTE) › Inspection of high-tension cords)

Maximum resistance: 25 kΩ per cord

Inspection of spark plugs (5S-FE only)¶

(See On-vehicle inspection (5S-FE) › Inspection of high-tension cords)

Correct electrode gap: 1.1 mm (0.043 in.)

Recommended spark plugs:

• ND K16R-U11
• NGK BKR5EYA11

Inspection and adjustment of alternator drive belt¶

(See On-vehicle inspection, step 3)

Drive belt tension:

• New belt – 120 ± 20 lb
• Used belt – 104 ± 20 lb

Inspection and adjustment of valve clearance (3S-GTE)¶

1. Disconnect cable from negative terminal of battery.

   Caution

   Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.

2. Remove No.1 air intake connector. (See Intercooler, step 4)

3. Disconnect high-tension cords from spark plugs. (See On-vehicle inspection (3S-GTE) › Inspection of high-tension cords)
4. Remove EGR vacuum modulator and VSV. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 22)
5. Remove throttle body. (See steps 3, 5 to 8, 10 and 11 on pages FI-135 and 136)
6. Remove hose clamp and VTV clamp of air by-pass valve. (See Turbocharger › Removal of turbocharger, steps 15, 16)
7. Remove cylinder head cover. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 35)

8. Set No.1 cylinder to TDC/compression.

   1. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover.
   2. 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.

   

9. Inspect valve clearance.

   1. Check only those valves indicated.

      • Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
      • Record the specifications of the valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

      Valve clearance (cold):

      • Intake – 0.15 – 0.25 mm (0.006 – 0.010 in.)
      • Exhaust – 0.20 – 0.30 mm (0.008 – 0.012 in.)

      

   2. Turn the crankshaft one revolution (360°) and align the mark as above. (See procedure step 8)

   3. Check only the valves indicated as shown. Measure the valve clearance. (See procedure step (a))

      

10. Adjust valve clearance.

    1. 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 (B) 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.

       

       • Remove the adjusting shim with small screwdriver and magnetic finger.

       

    2. 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.

         Symbol	Meaning
         T	Thickness of used shim
         A	Measured valve clearance
         N	Thickness of new shim

         • Intake — N = T + (A – 0.20 mm (0.008 in.))
         • Exhaust — N = T + (A – 0.25 mm (0.010 in.))

       • Select a new shim with a thickness as close as possible to the calculated valve.

       Hint

       Shims are available in twenty-seven sizes of 0.05 mm (0.0020 in.), from 2.00 mm (0.0787 in.) to 3.30 mm (0.1299 in.).

       

    3. Install a new adjusting shim.

       • Place a new adjusting shim on the valve lifter.
       • Using SST (A), press down the valve lifter and remove SST (B).

       SST 09248-55010

       

    4. Recheck the valve clearance.

11. Reinstall cylinder head cover. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 7)

12. Install hose clamp and VTV clamp of air by-pass valve. (See Turbocharger › Installation of turbocharger, steps 13, 14)
13. Reinstall throttle body. (See steps 2, 3, 4 to 8 and 10 on pages FI-138 and 139)
14. Reinstall EGR vacuum modulator and VSV. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 20)
15. Reconnect high-tension cords from spark plugs.
16. Reinstall No.1 air intake connector. (See Intercooler › Installation of intercooler, step 10)
17. Connect cable to negative terminal of battery.

Adjusting shim selection using chart (3S-GTE)¶

Intake valve clearance (cold): 0.15 – 0.25 mm (0.006 – 0.010 in.)

Exhaust valve clearance (cold): 0.20 – 0.30 mm (0.008 – 0.012 in.)

New shim thickness — mm (in.):

Inspection and adjustment of valve clearance (5S-FE)¶

1. Disconnect high-tension cords from spark plugs. (See On-vehicle inspection (5S-FE) › Inspection of high-tension cords)
2. Remove cylinder head cover. (See Cylinder head (5S-FE) › Removal of cylinder head, step 32)

3. Set No.1 cylinder to TDC/compression.

   1. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover.
   2. Check that the valve lifters on the No.1 cylinder are loose and valve lifters on the No.4 are tight.

   If not, turn the crankshaft one revolution (360°) and align the mark as above.

   

4. Inspect valve clearance.

   1. Check only those valves indicated.

      • Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
      • Record out of the specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

      Valve clearance (cold):

      • Intake – 0.19 – 0.29 mm (0.007 – 0.011 in.)
      • Exhaust – 0.28 – 0.38 mm (0.011 – 0.015 in.)

      

   2. Turn the crankshaft one revolution (360°) and align the mark as above. (See procedure step 3)

   3. Check only the valves indicated as shown. Measure the valve clearance. (See procedure step (a))

      

5. Adjust valve clearance.

   1. 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 (B) 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.

      

      • Remove the adjusting shim with small screwdriver and magnetic finger.

      

   2. 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 specified value.

        Symbol	Meaning
        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 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).

      

   3. Install a new adjusting shim.

      • Place a new adjusting shim on the valve lifter.
      • Using SST (A), press down the valve lifter and remove SST (B).

      SST 09248-55010

      

   4. Recheck the valve clearance.

6. Reinstall cylinder head cover. (See Cylinder head (5S-FE) › Installation of cylinder head, step 7)

7. Reconnect high-tension cords to spark plugs.

Adjusting shim selection using chart (5S-FE)¶

Intake valve clearance (cold): 0.19 – 0.29 mm (0.007 – 0.011 in.)

Exhaust valve clearance (cold): 0.28 – 0.38 mm (0.011 – 0.015 in.)

New shim thickness — mm (in.):

Inspection and adjustment of ignition timing¶

• 3S-GTE (See Distributor (3S-GTE) › Installation of distributor)
• 5S-FE (See Distributor (5S-FE) › Installation of distributor)

Ignition timing: 10° BTDC @ idle (w/ terminals TE1 and E1 connected)

Inspection of idle speed (3S-GTE)¶

Initial conditions (See Inspection and adjustment of idle speed (5S-FE))

Idle speed: 800 ± 50 rpm

Inspection and adjustment of idle speed (5S-FE)¶

(See HINT on page FI-18)

1. Initial conditions.

   1. Engine at normal operating temperature
   2. Air cleaner installed
   3. All pipes and hoses of air induction system connected

   4. All vacuum lines connected

      Hint

      All vacuum hoses for EGR systems, etc. should be properly connected.

   5. EFI system wiring connectors fully plugged

   6. All operating accessories switched OFF
   7. Transmission in neutral range

2. Check ISC system. (See page FI-151)

3. Connect tachometer. (See Distributor (5S-FE) › Installation of distributor)

4. Adjust idle speed.

   1. Using SST, connect terminals TE1 and E1 of the check connector.

      SST 09843-18020

      Hint

      Decrease the rpm after the engine maintains a speed of the 1,000 – 1,300 rpm for 5 seconds.

      

   2. Check the idle speed.

      Idle speed: 650 rpm or more

   3. If the idle speed is not as specified, adjust the idle speed by turning the IDLE SPEED ADJUSTING SCREW.

      

   4. Remove SST.

      SST 09843-18020

      

5. Further check idle speed.

   Idle speed:

   • 750 ± 50 rpm — USA M/T
   • 700 ± 50 rpm — USA A/T
   • 850 ± 50 rpm — CANADA M/T
   • 750 ± 50 rpm — CANADA A/T

   If the idle speed is not within these values, carry out either of the below listed procedures and then recheck the idle speed.

   Carry out a driving test, including stop-go several times at a speed above 10 km/h, or start the engine, idle for 30 seconds and then turn the engine off repeatedly. By doing this, idle data will be stored in the ISC and the idle rpm will be at specified value.