Echo & Prius Toyota Corolla IX

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. On ECHO, remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. On Prius, remove air cleaner assembly located above the valve cover. On all models, disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect PCV hoses from valve cover.
2. Remove valve cover bolts/nuts, seal washers, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine.
3. Ensure timing marks on camshaft sprockets are facing upward at 12 o'clock position. (Scheme 24) If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment.
4. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. (Scheme 25) Record valve clearance.
5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 2 in illustration. (Scheme 25) Record valve clearance.
6. Ensure valve clearance is within specification. See «VALVE CLEARANCE SPECIFICATIONS (ECHO & PRIUS)»(ref-133193-S37436493022002021900000) table. VALVE CLEARANCE SPECIFICATIONS (ECHO & PRIUS) Application (1) In. (mm) Intake.006-.010 (.15-.25) Exhaust.010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.
7. If valve clearance requires adjustment, camshafts must be removed for access to valve lifters. Different thickness valve lifters are used. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Ensure camshafts are positioned so timing marks on camshaft sprockets are facing upward at 12 o'clock position. (Scheme 24)
8. Place reference marks on timing chain at both camshaft sprockets. (Scheme 26) Rotate crankshaft counterclockwise 40 degrees from TDC. Remove timing chain cover plug from front of timing chain cover. (Scheme 26)
9. Using screwdriver, rotate stopper plate on timing chain tensioner upward while rotating exhaust camshaft slightly clockwise and pushing plunger on timing chain tensioner inward. (Scheme 26) Once plunger on timing chain tensioner is pushed inward, move stopper plate downward and install a.08-.12" (2.0-3.0 mm) pin through stopper plate and into hole on timing chain tensioner to retain the plunger in retracted position. (Scheme 26) Use tape to secure pin in place.
10. Manufacturer recommends removing camshaft sprockets and camshafts with timing chain still engaged with crankshaft sprocket for access to valve lifter. To remove camshafts, see appropriate article in ENGINES. Secure timing chain aside to prevent timing chain from becoming disengaged from crankshaft sprocket. DO NOT allow timing chain to become disengaged from crankshaft sprocket.
11. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. see scheme 4 Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used for proper valve by using following equation, or using valve lifter selection charts. For intake valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus.0080" (.200 mm). For exhaust valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus.0120" (.300 mm). Valve lifters are available in 35 sizes ranging from.1992" (5.060 mm) to.2260" (5.740 mm) in increments of.0008" (.020 mm). For valve lifter selection charts see scheme 17and see scheme 18.
12. Install replacement valve lifter, camshafts and timing chain. Remove pin from timing chain tensioner. Ensure timing marks on camshaft sprockets are facing upward at 12 o'clock position and reference marks on timing chain at both camshaft sprockets are aligned when crankshaft pulley timing mark (groove) is aligned with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. (Scheme 24)and (Scheme 26).
13. Install NEW timing chain cover plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-133193-S27056277122002021900000). Recheck valve clearance. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. see scheme 15 Install gasket, valve cover, seal washers, bolts and nuts. Tighten valve cover bolts/nuts to specification in sequence. (Scheme 27) See «TORQUE SPECIFICATIONS»(ref-133193-S27056277122002021900000). To install remaining components, reverse removal procedure. Tighten ignition coil bolts to specification. See «TORQUE SPECIFICATIONS»(ref-133193-S27056277122002021900000).

Scheme 28

Scheme 29

Scheme 30

1. Remove air cleaner hose along with upper cap on air cleaner and mass airflow meter. Remove intake air connector for access to valve cover. Intake air connector fits between air cleaner hose and throttle body.
2. Disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect engine wiring, clamps and PCV hose for access to valve cover. Remove bolts, seal washers, valve cover and gasket.
3. Rotate crankshaft clockwise until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine.
4. Ensure 1-dot and 2-dot timing marks on camshaft sprockets are aligned. (Scheme 28) If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover.
5. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. (Scheme 29) Record valve clearance.
6. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance on specified valves. Perform STEP 2 in illustration. (Scheme 29) Record valve clearance.
7. Ensure valve clearance is within specification. See «VALVE CLEARANCE SPECIFICATIONS (TACOMA)»(ref-133193-S41664239142002021900000) table. VALVE CLEARANCE SPECIFICATIONS (TACOMA) Application (1) In. (mm) Intake.006-.010 (.15-.25) Exhaust.010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.
8. If valve clearance requires adjustment, rotate crankshaft so camshaft lobe on valve to be adjusted is facing upward, away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug.
9. Valve Clearance Adjuster (SST 09248-55040) is used to remove adjusting shim. Using SST "A" of valve clearance adjuster, press valve lifter downward. (Scheme 30) Install SST "B" between camshaft and valve lifter with side marked with No. 9 at designated position. (Scheme 30) Remove SST "A".
10. Using small screwdriver and magnet, remove adjusting shim. Using micrometer, measure thickness of adjusting shim removed. Using thickness of used adjusting shim and measured clearance, determine correct thickness of adjusting shim to be used for proper valve by using the follow equation, or using adjusting shim selection charts. For intake valves, "N" (new adjusting shim thickness) = "T" (used adjusting shim thickness) + "A" (measured clearance) minus.0080" (.200 mm). For exhaust valves, "N" (new adjusting shim thickness) = "T" (used adjusting shim thickness) + "A" (measured clearance) minus.0120" (.300 mm). Adjusting shims are available in 17 sizes ranging from.0984" (2.500 mm) to.1299" (3.300 mm) in increments of.0020" (.050 mm). For adjusting shim selection charts (Scheme 31)and (Scheme 32).
11. Install replacement adjusting shim. Recheck valve clearance. To install remaining components, reverse removal procedure. Install and tighten ignition coil bolts to specification. See «TORQUE SPECIFICATIONS»(ref-133193-S27056277122002021900000).

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. If Toyota hand-held tester is not available, go to next step. If Toyota hand-held tester is available, connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 41 Start engine and warm engine to normal operating temperature. Using hand-held tester manufacturers instructions, read ignition timing with engine idling. Ignition timing should be 8-12° BTDC. Shut engine off. Remove hand-held tester.
2. If Toyota hand-held tester is not available, start engine and warm engine to normal operating temperature. Shut engine off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Pull out wiring harness near ignition coil so timing light lead may be connected. (Scheme 33) Connect timing light lead to the wire in wiring harness.
3. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. see scheme 41 Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. (Scheme 34) Start engine. Engine speed should increase to 1000-1300 RPM for 5 seconds and return to idle.
4. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See «IGNITION TIMING SPECIFICATIONS»(ref-133193-S00155743352002021900000) table.
5. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See «IGNITION TIMING SPECIFICATIONS»(ref-133193-S00155743352002021900000) table. Increase engine speed and check that ignition timing advances when engine speed is increased. Allow engine to idle. Shut engine off. Remove timing light. Tape wire back to wiring harness. Reinstall No. 2 cylinder head cover.

Scheme 35

1. If Toyota hand-held tester is not available, go to next step. If Toyota hand-held tester is available, connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 42 Start engine and warm engine to normal operating temperature. Read ignition timing from CURRENT DATA on hand-held tester with engine idling. Ignition timing should be 8-12° BTDC. Shut engine off. Remove hand-held tester.
2. If Toyota hand-held tester is not available, start engine and warm engine to normal operating temperature. Shut engine off. Open wiring harness protector and pull out Black/White wire from wiring harness near ignition coil so timing light lead may be connected. (Scheme 35) Connect timing light lead to the Black/White wire in wiring harness.
3. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. see scheme 42 Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. (Scheme 34) Start engine. Engine speed should increase to 900-1500 RPM for 5 seconds and return to idle.
4. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See «IGNITION TIMING SPECIFICATIONS»(ref-133193-S00155743352002021900000) table.
5. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See «IGNITION TIMING SPECIFICATIONS»(ref-133193-S00155743352002021900000) table. Allow engine to idle. Shut engine off. Remove timing light. Place wire back into wiring harness protector.