ENGINE MECHANICAL VALVE CLEARANCE (1GRFE ......ENGINE MECHANICAL − VALVE CLEARANCE (1GR−FE) 14−9 LAND CRUISER PRADO Supplement (RM1017E) (c) Turn the crankshaft 2/3 of a revolution

1415S−02

A76530

A76504

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks

−ENGINE MECHANICAL VALVE CLEARANCE (1GR−FE)14−7

LAND CRUISER PRADO Supplement (RM1017E)

VALVE CLEARANCE (1GR−FE)ADJUSTMENT1. DRAIN ENGINE COOLANT (See page 16−5)2. REMOVE V−BANK COVER (See page 10−7)3. DISCONNECT VENTILATION HOSE NO.2 (See page 10−7)4. REMOVE AIR CLEANER ASSY (See page 10−7)5. REMOVE INTAKE AIR SURGE TANK (See page 14−58)6. REMOVE IGNITION COIL ASSY7. REMOVE CYLINDER HEAD COVER SUB−ASSY RH (See page 14−58)8. REMOVE CYLINDER HEAD COVER SUB−ASSY LH (See page 14−58)

9. SET NO. 1 CYLINDER TO TDC/COMPRESSION(a) Turn the crankshaft pulley, and align its groove with the

timing mark ”0” of the timing chain cover.

(b) Check that the timing marks of the camshaft timing gearsare aligned with the timing marks of the bearing cap asshown in the illustration.

If not, turn the crankshaft 1 complete revolution (360_) and alignthe timing marks as above.

A76343

6 6

2 2

Front1 1

3 3RH Bank:

LH Bank:

EX

IN

EX

IN

A76344

2 2

4 4

Front3 3

5 5RH Bank:

LH Bank:

EX

IN

EX

IN

14−8−ENGINE MECHANICAL VALVE CLEARANCE (1GR−FE)


10. INSPECT VALVE CLEARANCE(a) Check the valves indicated in the illustration.

(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.

Valve clearance (Cold):Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)(2) Record the out−of−specification valve clearance

measurements. They will be used later to determinethe required replacement valve lifter.

(b) Turn the crankshaft 2/3 of a revolution (240_), and checkthe valves indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-

tween the valve lifter and camshaft.Valve clearance (Cold):Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)(2) Record the out−of−specification valve clearance


A76345

4 4

6 6

Front5 5

1 1RH Bank:

LH Bank:

EX

IN

EX

IN

A76530

A76504

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks



(c) Turn the crankshaft 2/3 of a revolution (240_), and checkthe valves indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-

tween the valve lifter and camshaft.Valve clearance (Cold):Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)(2) Record the out−of−specification valve clearance


11. ADJUST VALVE CLEARANCE(a) Set No. 1 cylinder to TDC/compression.

(1) Turn the crankshaft pulley, and align the notch withthe timing mark ”0” of the timing chain cover.

(2) Check that the timing marks of the camshaft timinggears are aligned with the timing marks of the bear-ing cap as shown in the illustration.

If not, turn the crankshaft 1 complete revolution (360_) and alignthe timing marks as above.

A76505

Paint Marks

Timing Marks

A76506

A72958

Push

Stopper PlateStopperPlate

A76507

Raise



(3) Place paint marks on the No. 1 chain links that cor-respond with the timing marks of the camshaft tim-ing gears.

(b) Remove the chain tensioner assy No. 1.NOTICE:S Never rotate the crankshaft with the chain tensioner

removed.S When rotating the camshaft with the timing chain re-

moved, turn the crankshaft counterclockwise 40_from the TDC first.(1) Remove the 4 bolts, timing chain cover plate and

gasket.

(2) While rotating the stopper plate of the tensioner up-ward, push in the plunger of the chain tensioner asshown in the illustration.

(3) While rotating the stopper plate of the tensionerdownward, insert a bar of � 3.5 mm (0.138 in.) intothe holes in the stopper plate and tensioner to fix thestopper plate.

(4) Remove the 2 bolts and chain tensioner.(c) Remove the No. 2 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

(1) While raising up the chain tensioner No. 2, insert apin of � 1.0 mm (0.039 in.) into the hole to fix it.

A76508

A76509

A76510

1

2 4 8 6

573

A76511



(2) Hold the hexagonal portion of the No. 2 camshaftwith a wrench, and remove the camshaft timinggear set bolt.

NOTICE:Be careful not to damage the cylinder head and valve lifterwith the wrench.

(3) Separate the camshaft timing gear from the No. 2camshaft.

(4) Rotate the camshaft counterclockwise using thewrench so that the cam lobes of No. 1 cylinder facesupward as shown in the illustration.

(5) Using several steps, loosen and remove the 8 bear-ing cap bolts uniformly in the sequence as shown inthe illustration.

(6) Remove the 4 bearing caps and No. 2 camshaft.

(d) Remove the chain tensioner assy No. 2.(1) Remove the chain tensioner No. 2 bolt, and then re-

move the chain tensioner No. 2 and camshaft timinggear.

(e) Remove the camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

A76512

A76513

Slide

A76514

A76515

1

2 4 8 6

573

A76516



(1) Hold the hexagonal portion of the No. 1 camshaftwith a wrench, and loosen the camshaft timing gearset bolt.

NOTICE:S Be careful not to damage the cylinder head and valve

lifter with the wrench.S Do not disassemble the camshaft timing gear assem-

bly.

(2) Slide the camshaft timing gear and separate the No.1 chain from the camshaft timing gear.

(3) Rotate the No. 1 camshaft counterclockwise usingthe wrench so that the cam lobes of No. 1 cylinderfaces upward as shown in the illustration.


(5) Remove the 4 bearing caps.

(6) Remove the camshaft timing gear set bolt with theNo. 1 camshaft lifted up, and then remove the No.1 camshaft and camshaft timing gear w/ No. 2chain.

A76517

A76480

Push

A76481

A76482

1

2486

5 7 3



(7) Tie the No. 1 chain with a string as shown in the il-lustration.

NOTICE:Be careful not to drop anything inside the timing chain cov-er.(f) Remove the No. 4 camshaft sub−assy.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

(1) While pushing down the chain tensioner No. 3, in-sert a pin of � 1.0 mm (0.039 in.) into the hole to fixit.

(2) Hold the hexagonal portion of the No. 4 camshaftwith a wrench, and remove the camshaft timinggear set bolt.

NOTICE:Be careful not to damage the cylinder head and valve lifterwith the wrench.

(3) Separate the camshaft timing gear from the No. 4camshaft.


(5) Remove the 4 bearing caps and No. 4 camshaft.

A76483

A76809

1

2486

5 7 3

A76810

A76489



(g) Remove the chain tensioner assy No. 3.(1) Remove the chain tensioner No. 3 bolt, and then re-

move the chain tensioner No. 3 and camshaft timinggear.

(h) Remove the No. 3 camshaft sub−assy.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich received the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.


(2) Remove the 4 bearing caps.

(3) Hold the No. 1 chain, and remove the No. 3 cam-shaft, camshaft timing gear and No. 2 chain.

(4) Tie the No. 1 chain with a string as shown in the il-lustration.

NOTICE:Be careful not to drop anything inside the timing chain cov-er.(i) Remove the valve lifters.

A01082



(j) Determine the replacement valve lifter size according tothese Formula or Charts:(1) Using a micrometer, measure the thickness of the

removed lifter.(2) Calculate the thickness of a new lifter so that the

valve clearance comes within the specified value.T: Thickness of removed lifterA: Measured valve clearanceN: Thickness of new lifterIntake:N = T + (A − 0.20 mm (0.008 in.))Exhaust:N = T + (A − 0.34 mm (0.013 in.))(3) Select a new lifter with a thickness as close as pos-

sible to the calculated value.HINT: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 (0.2260in.).

A76341

ValveLifterSelectionChart(Intake)

Installedlifter

New

LifterThickness

mm(in.)

thickness

mm(in.)

Measure

clearancemm(in.)

No.

Thickness

No.

Thickness

No.

Thickness

Intake

valveclearance

(Cold):

0.15

to0.25

mm(0.0059to

0.0098

in.)

EXAMPLE

:The

5.250mm(0.2067in.)lifterisinstalled,andthe

measuredclearanceis0.400mm(0.0158in.).

Replace

the5.250mm(0.2067in.)lifterw

ithanew

No.46

lifter.



A76342

ValveLifterSelectionChart(Exhaust)

Installedlifter

New

LifterThickness

mm(in.)

thickness

mm(in.)

Measure

clearancemm(in.)

No.

Thickness

No.

Thickness

No.

Thickness

Exhaustvalveclearance

(Cold):

0.29

to0.39

mm(0.0114to

0.0154

in.)

EXAMPLE

:The

5.340mm(0.2102in.)lifterisinstalled,andthe

measuredclearanceis0.480mm(0.0189in.).

Replace

the5.340mm(0.2102in.)lifterw

ithanew

No.48

lifter.



A76490

Mark Links

Timing Marks

A76811

A76493

A76494



(k) Install the No. 3 camshaft sub−assy.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

(1) Align the mark link (yellow) with the timing mark (2dot marks) of the camshaft timing gear as shown inthe illustration.

(2) Apply new engine oil to the thrust portion and jour-nal of the camshafts.

(3) Temporarily put the No. 1 chain on the No. 2 chainof the camshaft timing gear.

(4) Set the No. 3 camshaft onto the LH cylinder headwith the cam lobes of the No. 2 cylinder faces down-ward as shown in the illustration.

(5) Install the 4 bearing caps in their proper locations.(6) Apply a light coat of engine oil on the threads of the

bearing cap bolts.

A76487

8

7513

4 2 6

A76495

Timing Marks

Paint Mark

A76289

Push

A76496Timing Marks

Mark Links



(7) Install the 8 bearing cap bolts. Using several steps,tighten the bolts uniformly in the sequence asshown in the illustration.

Torque:9.0 N�m (92 kgf�cm, 80 in.�lbf) for 10mm (0.39 in.) head24 N�m (245 kgf�cm, 18 ft�lbf) for 12 mm (0.47 in.) head

(8) Align the paint mark of the No. 1 chain with the tim-ing marks of the camshaft timing gear.

(l) Install the chain tensioner assy No. 3.(1) While pushing in the tensioner, insert a pin of � 1.0

mm (0.039 in.) into the hole to hold it.

(2) Temporarily install the camshaft timing gear andchain tensioner No. 3 and align the mark links (yel-low) with the timing marks (1 dot mark and 2 dotmarks) of the camshaft timing gears.

(3) Tighten the chain tensioner No. 3 bolt.Torque: 19 N�m (194 kgf�cm, 14 ft�lbf)

(m) Install the No. 4 camshaft sub−assy.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

A76497

A76498

A76482

8

7513

4 2 6

A76481



(1) Align the knock pin hole in the camshaft timing gearwith the knock pin of he No. 4 camshaft, and insertthe No. 4 camshaft into the camshaft timing gear.

(2) Temporarily install the camshaft timing gear set bolt.

(3) Install the 4 bearing caps in their proper locations.(4) Apply a light coat of engine oil on the threads and

under the heads of the bearing cap bolts.



(6) Hold the hexagonal portion of the No. 4 camshaftwith a wrench, and tighten the camshaft timing gearset bolt.

Torque: 100 N�m (1,020 kgf�cm, 74 ft�lbf)(7) Remove the pin from the chain tensioner No. 3.

(n) Install the camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

A76518

Mark Links

Timing Mark

A76519

A76520

Knock Pin

A76521

A76522



(1) Align the mark link (yellow) with the timing mark (1dot mark) of the camshaft timing gear as shown inthe illustration.

(2) Apply new engine oil to the thrust portion and jour-nal of the camshafts.

(3) Temporarily put the No. 1 chain on the No. 2 chainof the camshaft timing gear.

(4) Align the knock pin hole in the camshaft timing gearwith the knock pin of the No. 1 camshaft, and insertthe No. 1 camshaft into the camshaft timing gear.

(5) Temporarily install the camshaft timing gear set bolt.

(6) Set the No. 1 camshaft onto the RH cylinder headwith the cam lobes of the No. 1 cylinder faces down-ward as shown in the illustration.



A76515

8

7 5 1 3

426

A76523

Timing Marks

A76524

Paint Mark

Timing Mark

A76512

A76286

Push





(10) Rotate the No. 1 camshaft clockwise using hexago-nal portion of the No. 1 camshaft so that the timingmark of the camshaft timing gear is aligned with thetiming marks of the camshaft bearing cap.

(11) Align the paint mark of the No. 1 chain with the tim-ing mark of the camshaft timing gear.

(12) Hold the hexagonal portion of the No. 1 camshaftwith a wrench, and tighten the camshaft timing gearset bolt.

Torque: 100 N�m (1,020 kgf�cm, 74 ft�lbf)

(o) Install the chain tensioner assy No. 2.(1) While pushing in the tensioner, insert a pin of � 1.0

mm (0.039 in.) into the hole to fix it.

A76525

Mark Links

Timing Marks

A76526

A76527

A76510

8

7 5 1 3

426



(2) Temporarily install the camshaft timing gear andchain tensioner No. 2 and align the mark links (yel-low) with the timing marks (1 dot mark) of the cam-shaft timing gears.

(3) Tighten the chain tensioner No. 2 bolt.Torque: 19 N�m (194 kgf�cm, 14 ft�lbf)

(p) Install the No. 2 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich are received the shaft thrust may crack or be dam-aged, causing the camshaft to seize or break. To avoid this,the following steps should be carried out.

(1) Set the No. 2 camshaft onto the RH cylinder headwith the cam lobes of No. 1 cylinder faces upwardas shown in the illustration.





A76528

Knock Pin

A76508

A76294PushStopper Plate

Stopper Plate

A76530



(5) Rotate the No. 2 camshaft clockwise using thewrench so that the knock pin of the No. 2 camshaftis aligned with the knock pin hole of the camshafttiming gear.

(6) Hold the hexagonal portion of the No. 2 camshaftwith a wrench, and install the camshaft timing gearset bolt.

Torque: 100 N�m (1,020 kgf�cm, 74 ft�lbf)(7) Remove the pin from the chain tensioner No. 2.

(q) Install the chain tensioner assy No. 1.(1) While turning the stopper plate of the tensioner

clockwise, push in the plunger of the tensioner asshown in the illustration.

(2) While turning the stopper plate of the tensionercounterclockwise, insert a bar of � 3.5 mm (0.138in.) into the holes in the stopper plate and tensionerto fix the stopper plate.

(3) Install the chain tensioner with the 2 bolts.Torque: 9.0 N�m (92 kgf�cm, 80 in.�lbf)(4) Remove the bar from the chain tensioner.(5) Install a newgasket and the timing chain cover plate

with the 4 bolts.Torque: 9.0 N�m (92 kgf�cm, 80 in.�lbf)

(6) Turn the crankshaft pulley 2 complete revolutionsslowly, and align the notch with the timing mark ”0”of the timing chain cover.

A76504

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks



(7) Check that the timing marks of the camshaft timinggears are aligned with the timing marks of the bear-ing cap as shown in the illustration.

12. INSTALL CYLINDER HEAD COVER SUB−ASSY LH (See page 14−58)13. INSTALL CYLINDER HEAD COVER SUB−ASSY RH (See page 14−58)14. INSTALL IGNITION COIL ASSY

Torque: 9.0 N�m (92 kgf�cm, 80 in. �lbf)15. INSTALL INTAKE AIR SURGE TANK (See page 14−58)16. INSTALL AIR CLEANER ASSY (See page 10−7)17. CONNECT VENTILATION HOSE NO.218. ADD ENGINE COOLANT (See page 16−5)19. CHECK FOR ENGINE COOLANT LEAKS (See page 16−1)20. INSTALL V−BANK COVER(a) Install the V−bank cover with the 2 nuts.

Torque: 7.5 N�m (76 kgf�cm, 66 in.�lbf)21. INSPECT IGNITION TIMING (See page 14−1)

SST 09843−18040

Documents

ENGINE MECHANICAL VALVE CLEARANCE (1GRFE ......ENGINE MECHANICAL − VALVE CLEARANCE (1GR−FE) 14−9 LAND CRUISER PRADO Supplement (RM1017E) (c) Turn the crankshaft 2/3 of a revolution