Valve Clearance: Adjustments
Valve Lifter Selection Chart (Intake Part 1):
Valve Lifter Selection Chart (Intake Part 2):
Valve Lifter Selection Chart (Exhaust Part 1):
Valve Lifter Selection Chart (Exhaust Part 2):
VALVE CLEARANCE ADJUSTMENT
1. REMOVE REAR NO. 2 FLOOR BOARD
2. REMOVE REAR DECK FLOOR BOX
3. REMOVE REAR NO. 3 FLOOR BOARD
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE WIPER ARM HEAD CAP
7. REMOVE FRONT WIPER ARM LH
8. REMOVE FRONT WIPER ARM RH
9. REMOVE HOOD TO COWL TOP SEAL
10. REMOVE COWL TOP VENTILATOR LOUVER LH
11. REMOVE COWL TOP VENTILATOR LOUVER RH
12. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
13. REMOVE FRONT COWL TOP PANEL OUTER
14. REMOVE RADIATOR SUPPORT OPENING COVER
15. REMOVE AIR CLEANER ASSEMBLY
16. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR
17. REMOVE RESERVOIR BRACKET
18. REMOVE CYLINDER HEAD COVER
19. INSPECT VALVE CLEARANCE
HINT: Inspect and adjust the valve clearance when the engine is cold.
a. Set the No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned.
2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
b. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard Valve Clearance (Cold):
2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
c. Turn the crankshaft 1 complete revolution until its timing notch and timing mark 0 of the chain cover are aligned.
d. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard Valve Clearance (Cold):
2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
20. ADJUST VALVE CLEARANCE
a. Set the No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned.
2. Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
3. Put paint marks on the timing chain where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.
b. Using an 8 mm hexagon wrench, remove the screw plug.
c. Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner at an upward position.
HINT: Lifting up the stopper plate of the chain tensioner unlocks the plunger.
d. Keeping the stopper plate of the chain tensioner lifted, slightly rotate the hexagonal lobe of the No. 2 camshaft to the right with an adjustable wrench so the plunger of the chain tensioner is pushed.
HINT: When the camshaft No. 2 is slightly rotated to the right, the plunger is pushed.
e. Keeping the adjustable wrench installed, remove the screwdriver with the plunger pushed.
NOTICE: Do not move the adjustable wrench.
HINT: Removing the screwdriver lowers the stopper plate and locks the plunger.
f. Insert a 3.0 mm (0.118 inch) diameter bar into the hole of the stopper plate with the stopper plate of the chain tensioner lowered and locked.
HINT: If a 3.0 mm (0.118 inch) diameter bar cannot be inserted into the hole of the stopper plate, rotate the No. 2 camshaft slightly to the left and right. Then a 3.0 mm (0.118 inch) diameter bar can be inserted easily
g. Secure the 3.0 mm (0.118 inch) diameter bar with tape.
h. Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench.
i. Using SST, loosen the bolt.
SST 09023-38400
j. Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps.
NOTICE: Loosen each bolt uniformly, keeping the camshaft level.
k. Remove the flange bolt with the No. 2 camshaft lifted up. Then detach the No. 2 camshaft and the camshaft timing sprocket.
l. Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Then remove the 4 bearing caps.
NOTICE: Loosen each bolt uniformly, keeping the camshaft level.
m. Hold the timing chain with one hand, and remove the camshaft and the camshaft timing gear assembly.
n. Tie the timing chain with a string as shown in the illustration.
NOTICE: Be careful not to drop anything inside the timing chain cover.
o. Remove the valve lifters.
p. Using a micrometer, measure the thickness of the removed lifter.
q. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
New Lifter Thickness:
r. Select a new lifter with the thickness as close to the calculated values as possible.
EXAMPLE: (Intake)
Measured valve clearance = 0.40 mm (0.0158 inch) 0.40 mm (0.0158 inch) - 0.20 mm (0.0079 inch) = 0.20 mm (0.0079 inch)
(Measured - Specification Excess clearance) Used lifter measurement = 5.25 mm (0.2067 inch) 0.20 mm (0.0079 inch) + 5.25 mm (0.2067 inch) = 5.45 mm (0.2146 inch)
(Excess clearance + Used lifter = Ideal new lifter) Closest new lifter = 5.45 mm (0.2146 inch) Select No. 46 lifter (5.46 mm (0.2150 inch))
HINT:
^ Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).
^ Refer to the New lifter thickness table.
Valve Lifter Selection Chart (Intake Part 1):
1. Valve lifter selection chart (intake)
Valve Lifter Selection Chart (Intake Part 2):
2. Valve lifter selection chart (intake) (continued).
New Lifter Thickness (Part 1):
New Lifter Thickness (Part 2):
Standard intake valve clearance (Cold): 0.17 to 0.23 mm (0.007 to 0.009 inch)
EXAMPLE: A 5.250 mm (0.2067 inch) lifter is installed, and the measured clearance is 0.400 mm (0.0158 inch).
Replace the 5.250 mm (0.2067 inch) lifter with a new No. 46 lifter.
Valve Lifter Selection Chart (Exhaust Part 1):
3. Valve lifter selection chart (exhaust).
Valve Lifter Selection Chart (Exhaust Part 2):
4. Valve selection chart (exhaust) (continued).
New Lifter Thickness (Part 1):
New Lifter Thickness (Part 2):
Standard exhaust valve clearance (Cold): 0.27 to 0.33 mm (0.011 to 0.013 inch)
EXAMPLE: A 5.340 mm (0.2102 inch) lifter is installed, and the measured clearance is 0.440 mm (0.0173 inch).
Replace the 5.340 mm (0.2102 inch) lifter with a new No. 48 lifter.
s. Reinstall the selected valve lifters.
t. Apply a light coat of engine oil to the camshaft journals.
u. Install the timing chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.
v. Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (130 kgf-cm, 9.6 ft. lbs.)
NOTICE: Tighten each bolt uniformly, keeping the camshaft level.
w. Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the timing chain.
x. Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket into the camshaft.
y. Temporarily install the timing sprocket bolt.
z. Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (133 kgf-cm, 9 ft. lbs.)
NOTICE: Tighten each bolt uniformly, keeping the camshaft level.
aa. Install the No. 1 bearing cap.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
ab. Hold the hexagonal lobe of the No. 2 camshaft with the adjustable wrench.
ac. Using SST, tighten the bolt.
SST 09023-38400
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
ad. Remove the bar from the timing chain tensioner.
ae. Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned.
af. Check that all the pairs of the timing marks are aligned.
ag. Apply seal packing to 2 or 3 threads of the screw plug end.
Seal packing: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
ah. Using an 8 mm hexagon wrench, install the screw plug.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
21. INSTALL CYLINDER HEAD COVER
22. INSTALL RESERVOIR BRACKET
23. INSTALL BRAKE MASTER CYLINDER RESERVOIR
24. INSTALL AIR CLEANER ASSEMBLY
25. INSTALL FRONT COWL TOP PANEL OUTER
26. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
27. INSTALL COWL TOP VENTILATOR LOUVER RH
28. INSTALL COWL TOP VENTILATOR LOUVER LH
29. INSTALL HOOD TO COWL TOP SEAL
30. INSTALL FRONT WIPER ARM LH
31. INSTALL FRONT WIPER ARM RH
32. INSTALL WIPER ARM HEAD CAP
33. CHECK ENGINE OIL LEAKS
34. INSTALL RADIATOR SUPPORT OPENING COVER
35. REMOVE ENGINE UNDER COVER RH
36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
37. INSTALL REAR NO. 3 FLOOR BOARD
38. INSTALL REAR DECK FLOOR BOX
39. INSTALL NO. 2 REAR FLOOR BOARD
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.