Valve Clearance: Adjustment

REMOVE CYLINDER HEAD COVER NO.2
1. Remove the 4 nuts and the cylinder head cover No.2.
  
  Fig 1: Removing Cylinder Head Cover No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IGNITION COIL No. 1
1. Remove the 4 bolts and pull out the 4 ignition coils.
  
  Fig 2: Removing Ignition Coils
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT VENTILATION HOSE
1. Disconnect the ventilation hose from the cylinder head cover.
  
  Fig 3: Disconnecting Ventilation Hose From Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT VENTILATION HOSE NO.2
1. Disconnect the ventilation hose No.2 from the cylinder head cover.
  
  Fig 4: Disconnecting Ventilation Hose No. 2 From Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSY
1. Remove the 9 bolts, the 2 nuts and cylinder head cover.
REMOVE ENGINE UNDER COVER RH

Fig 5: Removing Cylinder Head Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE CLEARANCE
HINT:

Inspect and adjust the valve clearance when the engine is cold.
1. Set the No. 1 cylinder to TDC/compression.
  1. Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
  2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear facing upward as shown in the illustration.
    HINT:
    
    If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
    
    Fig 6: Identifying Timing Marks On Camshaft Timing Sprocket & Camshaft Timing Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valves indicated in the illustration.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold) :
    
    Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.)
  2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
3. Turn the crankshaft 1 complete revolution until its timing notch and the timing mark "0" of the chain cover are aligned.
  
  Fig 7: Setting No. 1 Cylinder To TDC/Compression
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the valves indicated in the illustration.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold) :
    
    Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.)
  2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
    
    Fig 8: Setting No. 4 Cylinder To TDC/Compression
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST VALVE CLEARANCE

NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves.

Fig 9: Rotating Crankshaft Damper Counterclockwise 40° From TDC & Align Its Timing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Set the No. 1 cylinder to the TDC/compression.
1. Turn the crankshaft damper 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.
  HINT:
  
  If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
  
  Fig 10: Identifying Timing Marks On Camshaft Timing Sprocket & Valve Timing Controller Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Put paint marks on the timing chain in place where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.

Fig 11: Putting Paint Marks On Timing Chain
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using an 8 mm hexagon wrench, remove the screw plug.

Fig 12: Removing Screw Plug
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Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner at upward position.
Using a wrench, rotate the camshaft No.2 clockwise to push in the plunger of the chain tensioner.

Fig 13: Pushing In Plunger Of Chain Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the screwdriver from the service hole, then align the hole of the stopper plate with the service hole and insert a 2 to 3 mm (0.08 to 0.12 in.) diameter bar into the holes to hold the stopper plate.
HINT:
- Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
- Hold the bar with tape so that the bar does not come off.
Hold the camshaft with a wrench on the hexagonal lobe, and remove the bolt.
SST 09023-38401

Fig 14: Removing Camshaft Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
NOTE: Loosen each bolt uniformly keeping the camshaft level.

Fig 15: Identifying Removal Sequence Of Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the fringe bolt with the No.2 camshaft lifted up, then detach the No.2 camshaft and the camshaft timing sprocket.

Fig 16: Removing Fringe Bolt
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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.
NOTE: Loosen each bolt uniformly keeping the camshaft level.

Fig 17: Identifying Removal Sequence Of Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Hold the timing chain by hand, and remove the camshaft and the camshaft timing gear assembly.

Fig 18: Removing Camshaft & Camshaft Timing Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tie the timing chain with a string as shown in the illustration.
NOTE: Be careful not to drop anything inside the timing chain cover.

Fig 19: Tie Timing Chain With String
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the valve lifters.
Using a micrometer, measure the thickness of the removed lifter.

Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

LIFTER THICKNESS

A	Thickness of new lifter
B	Thickness of used lifter
C	Measured valve clearance

Specified value (Cold):

Intake A = B + (C - 0.20 mm (0.008 in.))

Exhaust A = B + (C - 0.30 mm (0.012 in.))

Fig 20: Measuring Thickness Of Removed Lifter

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 in.)

0.40 mm (0.0158 in.) - 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.)

(Measured - Specification = Excess clearance)

Used lifter measurement = 5.25 mm (0.2067 in.)

0.20 mm (0.0079 in.) + 5.25 mm (0.2067 in.) = 5.45 mm (0.2146 in.)

(Excess clearance + Used lifter = Ideal new lifter)

Closest new lifter = 5.45 mm (0.2146 in.)

Select No. 46 lifter (5.46 mm (0.2150 in.))

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 (0.2260 in.).
- Refer to the New Lifter Thickness table .
Fig 21: Intake Valve Lifter Selection Table
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 22: Exhaust Valve Lifter Selection Table
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Reinstall the valve lifters.
Apply a light coat of engine oil to the camshaft journals.
Install the timing chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.

Fig 23: Installing Timing Chain Onto Camshaft Timing Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 N.m (129 kgf.cm, 9.4 ft.lbf)

NOTE: Tighten each bolt uniformly keeping the camshaft level.

Fig 24: Identifying Tightening Sequence Of Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Hold the timing chain, and align the match mark on the camshaft timing sprocket with the paint mark of the timing chain.

Fig 25: Aligning Match Mark On Camshaft Timing Sprocket With Paint Mark Of Timing Chain
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket into the camshaft.
Temporarily install the timing sprocket bolt.

Fig 26: Installing Timing Sprocket Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 N.m (129 kgf.cm, 9.4 ft.lbf)

NOTE: Tighten each bolt uniformly keeping the camshaft level.
Install the bearing cap No. 1.
Torque: 23 N.m (235 kgf.cm, 17 ft.lbf)

Fig 27: Identifying Tightening Sequence Of Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Hold the camshaft with a wrench on the hexagon lobe, and install the bolt.
Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)

SST 09023-38401
Remove the bar from the timing chain tensioner.

Fig 28: Installing Camshaft Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
Check that all the pairs of the timing marks are aligned.

Fig 29: Aligning Timing Marks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply seal packing to 2 or 3 threads of the screw plug end.
Seal packing:

Part No. 08833 - 00070 or equivalent
Using an 8 mm hexagon wrench, install the screw plug.
Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)

Fig 30: Installing Screw Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CYLINDER HEAD COVER SUB-ASSY
1. Apply seal packing to the 2 locations shown in the illustration.
  Seal packing: Part No. 08826 - 00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes of applying seal packing.
  - Do not start the engine for at least 2 hours of installation.
    
    Fig 31: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cylinder head cover with the 9 bolts, the 2 seal washers and the 2 nuts.
3. Using several steps, uniformly tighten the bolts and the nuts in the sequence shown in the illustration.
  Torque: 10 N.m (102 kgf.cm, 7.4 ft.lbf)
INSTALL IGNITION COIL No. 1
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)

Fig 32: Installing Cylinder Head Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER NO.2
1. First tighten A nuts, then tighten bolts B.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
  
  Fig 33: Installing Cylinder Head Cover No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR ENGINE OIL LEAKS