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Valve Clearance: MR2

WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 2003 Toyota Tacoma, 2003 Toyota RAV4, 2003 Toyota Prius, 2003 Toyota Matrix, and 2003 Toyota MR2. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. 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 reference marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover. See Fig 1. If reference 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 reference 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. See Fig 2. 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 on specified valves. Perform STEP 2 in illustration. See Fig 2. Record valve clearance.
  6. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (MR2)  table.
    VALVE CLEARANCE SPECIFICATIONS (MR2)

    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. Manufacturer recommends placing reference mark on timing chain and camshaft sprockets, removing timing chain tensioner and then removing camshaft sprockets and camshafts for access to valve lifter while supporting timing chain. To remove camshafts, see appropriate article in ENGINES.
  8. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. See Figure. Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used for proper valve by using the follow 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 Fig 5 and Fig 6 .
  9. Install replacement valve lifter, camshafts and timing chain. Recheck valve clearance. To ensure proper valve timing after reinstalling camshafts and timing chain, check that reference marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover 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. See Fig 1.
  10. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig 3. Install gasket, valve cover, seal washers, bolts and nuts. Tighten valve cover bolts/nuts to specification in sequence. See Fig 4. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .
Fig 1: Checking Reference Mark Alignment (MR2)
G00016729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Identifying Cylinder Numbers & Checking Valve Clearance (MR2)
G98E11217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Locating Valve Cover Sealant Application Areas (MR2)
G98A11221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Typical Valve Cover Bolt/Nut Tightening Sequence (MR2)
G98B11222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Intake Valve Lifter Selection Chart (MR2)
G98G11219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Exhaust Valve Lifter Selection Chart (MR2)
G98J11220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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