Warning: Wait until the engine is f\ co,d before starting this procedure. Do not allow antifreeze to come in contact with your skin, or with the painted surfaces of the vehicle. Rinse off spills immediately with plenty of water. Never leave antifreeze lying around in an open container, or in a puddle in the driveway or on the garage floor. Children and pets are attracted by its sweet smell, but antifreeze can be fatal if ingested.
1 If the engine is cold, unscrew and remove the pressure cap from the radiator. If it is not possible to wait until the engine is cold, place a cloth over the pressure cap and slowly unscrew it. Wait until all pressure has escaped, then remove the cap.
hand side of the radiator and the front or rear of the cylinder block, and suitable containers should be placed beneath these to catch the flow of escaping coolant prior to removing them (see illustration).
3 With all the coolant drained into the containers, tighten the drain plugs; if the system needs to be flushed after draining refer to the following sub-section.
4 When draining the cooling system, do not forget about the coolant in the expansion tank. The heater hoses and matrix also contain engine coolant, although no recommendations are made to attend to this as the relatively small amount of coolant will circulate back into the main volume of coolant in the engine during heater usage.
Every 36 000 miles 1.19
Radiator drain plug
Radiator drain plug
4A-FE and 7A-GEengines Engine drain
36.2 Radiator and cylinder block (engine) drain plug locations
5 If coolant renewal has been neglected, or if the antifreeze mixture has become diluted then, in time, the cooling system may gradually lose efficiency, as the coolant passages become restricted due to rust, scale deposits, and other sediment. The cooling system efficiency can be restored by flushing the system clean.
6 The radiator should be flushed independently of the engine, to avoid unnecessary contamination.
7 To flush the radiator disconnect the top and bottom hoses from the radiator.
8 Insert a garden hose into the radiator top inlet. Direct a flow of clean water through the radiator, and continue flushing until clean water emerges from the radiator bottom outlet.
9 If after a reasonable period, the water still does not run clear, the radiator can be flushed with a good proprietary cooling system cleaning agent. It is important that the manufacturer's instructions are followed carefully. If the contamination is particularly bad, remove the radiator then insert the hose in the radiator bottom outlet, and reverse-flush the radiator.
10 To flush the engine, remove the thermostat as described in Chapter 3 then temporarily refit the thermostat cover to enable the water to run out through the disconnected bottom hose and not all over the transmission.
11 With the top and bottom hoses disconnected from the radiator, insert a garden hose into the radiator top hose. Direct a clean flow of water through the engine, and continue flushing until clean water emerges from the radiator bottom hose.
12 On completion of flushing, refit the thermostat and reconnect the hoses with reference to Chapter 3.
13 Before attempting to fill the cooling system, reconnect all hoses and make sure that all clips are in good condition and tight. Note that an antifreeze mixture must be used all year round, to prevent corrosion of the engine components (see following sub-Section).
14 Fill the system slowly through the radiator filler until the level reaches the bottom of the filler neck. While filling, compress the radiator hoses frequently to purge air locks from the system.
15 Fill the expansion tank with coolant to the MAX level mark.
16 With the radiator cap still removed, start the engine and allow it to idle until heat can be felt through the radiator top hose. Accelerate the engine briefly several times, then switch off the ignition and allow the engine to cool (preferably for an hour).
17 Top up the level in the radiator to the filler neck and refit the radiator cap. Top up the level in the expansion tank to the MAX mark.
18 Start the engine and run it at 3000 rpm for half a minute. Stop the engine then remove the radiator cap and top up the level if necessary. Refit the cap.
19 Check for leaks, particularly around disturbed components.
20 The antifreeze should always be renewed at the specified intervals. This is necessary not only to maintain the antifreeze properties, but also to prevent corrosion which would otherwise occur as the corrosion inhibitors become progressively less effective.
21 Always use an ethylene-glycol based antifreeze which is suitable for use in mixed-metal cooling systems. The quantity of antifreeze and levels of protection are indicated in the Specifications.
22 Before adding antifreeze, the cooling system should be completely drained, preferably flushed, and all hoses checked for condition and security.
23 After filling with antifreeze, a label should be attached to the expansion tank, stating the type and concentration of antifreeze used, and the date installed. Any subsequent topping-up should be made with the same type and concentration of antifreeze.
24 Do not use engine antifreeze in the washer system, as it will cause damage to the vehicle paintwork. A screenwash additive should be added to the washer system In the quantities stated on the bottle.
37.4 Checking the valve clearances with a feeler gauge
37 Valve clearance check and adjustment ^
Every 54 000 miles (90 000 km)
1 The valve clearances must be checked and adjusted with the engine cold.
2 Remove the camshaft cover as described in Chapter 2A, Section 4.
3 Set No 1 piston at TDC compression as described in Chapter 2A, Section 3.
4 Using feeler blades, check and record the clearances of the following valves; the feeler blade should be a firm sliding fit between the shim on the follower and the camshaft lobe (see illustration).
Inlet camshaft No 1 inlet valves
Inlet camshaft No 2 inlet valves
Exhaust camshaft No 1 exhaust valves Exhaust camshaft No 3 exhaust valves
5 Using a socket on the crankshaft pulley, turn the engine 360° clockwise and align the notch in the pulley with the 0° mark on the timing belt cover. This will set No 4 piston at TDC on compression.
6 Using feeler blades, check and record the clearances of the following valves; the feeler blade should be a firm sliding fit between the shim on the follower and the camshaft lobe.
Inlet camshaft No 3 inlet valves
Inlet camshaft No 4 inlet valves
Exhaust camshaft No 2 exhaust valves Exhaust camshaft No 4 exhaust valves
37.4 Checking the valve clearances with a feeler gauge
1-20 Every 54 000 miles
7 Compare the recorded clearances with the clearances given in the Specifications, and note the valves which require adjustment.
8 If adjustment is required on the inlet valves of 4A-FE and 7A-FE engines, it will be necessary to remove the inlet camshaft as described in Chapter 2A in order to remove existing shims and fit new ones. For the exhaust valves of these engines, and for all valves of other engines, the shims can be replaced without removing the camshafts provided that a special Toyota tool is obtained to depress and hold the camshaft followers down. With the camshaft follower held depressed, the shim is removed using a suitable screwdriver and a magnetic probe (possibly another magnetised screwdriver). It should be possible to use a suitable alternative tool to depress and hold the camshaft followers down, however, if the tool is not available the camshafts can be removed by following the procedure described in Chapter 2A and the shim removed using a small screwdriver (see illustration). Adjustment should be made on each valve separately to ensure the shims are fitted in the correct locations.
9 Measure the thickness of the removed shim using a micrometer (see illustration), then calculate the thickness of the required shim using the following formula where the variables are T (the thickness of the removed shim), A (the valve clearance measured), V (the required valve clearance as given in the Specifications) and N (the thickness of the new shim required):
N = T + (A - V) Shims are available in a variety of sizes, and
the shim selected (from your Toyota dealer's parts department) should be as close as possible to the calculated value.
10 Install the new shim on the follower, with its thickness marking facing downwards.
11 Repeat the process for all the remaining shims that require renewal, then refit the camshafts (if removed) with reference to Chapter 2A.
12 On completion refit the camshaft cover as described in Chapter 2A, Section 4.
38 Timing belt renewal %
Refer to the procedures contained in Chapter 2A.
Every 63 000 miles (105 000 km)
Chapter 2 Part A:
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