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Celica 1.8L 2ZZ-GE

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  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 bolts/nuts and disconnect ventilation hose with and ventilation pipe and gasket from front corner of valve cover. Remove valve cover bolts, valve cover and gasket.
  3. 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.
  4. Ensure reference marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover. See Figure. 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.
  5. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between rocker arm and camshaft lobe on both valves on specified cylinders. Perform STEP 1 in illustration. See Fig 1. 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 between rocker arm and camshaft lobe on both valves on specified cylinders. Perform STEP 2 in illustration. See Fig 1. Record valve clearance.
    Fig 1: Identifying Cylinder Numbers & Checking Valve Clearance (Celica 1.8L 2ZZ-GE)
    G00014905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (CELICA 1.8L 2ZZ-GE)  table.
    VALVE CLEARANCE SPECIFICATIONS (CELICA 1.8L 2ZZ-GE)

    Application (1) In. (mm)
    Intake .003-.007 (.08-.19)
    Exhaust .008-.013 (.22-.33)
    (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, remove spark plug on cylinder in which valve clearance adjustment is required so compression is released. Rotate crankshaft so rocker arm for valve to be adjusted is pushed fully downward by the camshaft lobe. Perform STEP 1 in illustration. See Fig 2.
  9. Install Valve Spring Compressor (SST 09248-77010) on spark plug tube. Perform STEP 2 in illustration. See Fig 2. Set screw must be loosened so valve spring compressor fully seats on spark plug tube. Operate lever so plate fully seats against valve spring retainer and tighten set screw. Perform STEP 3 in illustration. See Fig 2. Ensure no clearance exists between plate and valve spring retainer, as any clearance may cause the valve keeper to be released.
  10. Carefully rotate crankshaft so camshaft lobe is positioned upward, away from rocker arm. Ensure camshaft lobe does not contact valve spring compressor when rotating camshaft. Lift rocker arm assembly upward. Using Adjusting Shim Remover/Installer (SST 09248-07020), remove adjusting shim from top of valve stem. Perform STEP 4 in illustration. See Fig 2.
    Fig 2: Removing & Installing Adjusting Shim (Celica 1.8L 2ZZ-GE)
    G00014901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Using dial indicator, measure thickness of removed adjusting shim. See Fig 3. 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 .0051" (.130 mm). For exhaust valves, "N" (new adjusting shim thickness) = "T" (used adjusting shim thickness) + "A" (measured clearance) minus .0106" (.270 mm). Adjusting shims are available in 41 sizes ranging from .0787" (2.000 mm) to .1102" (2.800 mm) in increments of .0008" (.020 mm). For adjusting shim selection charts, see Fig 4 and Fig 5 .
  12. Lift rocker arm assembly upward. Using adjusting shim remover/installer, install replacement adjusting shim. Rotate crankshaft so rocker arm is pushed fully downward by the camshaft lobe. Ensure camshaft lobe does not contact valve spring compressor when rotating camshaft. Operate lever to remove plate from valve spring retainer. Loosen set screw and remove valve spring compressor. Recheck valve clearance.
  13. Install spark plug and tighten to 13 ft. lbs. (18 N.m). Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Figure. Install gasket, valve cover and valve cover bolts. Tighten valve cover bolts to specification. See TORQUE SPECIFICATIONS .
  14. Using NEW gasket, install ventilation pipe. Tighten ventilation pipe bolts/nuts to specification. See TORQUE SPECIFICATIONS . Install ignition coils. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .
Fig 3: Measuring Adjusting Shim Thickness (Celica 1.8L 2ZZ-GE)
G99F50596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Intake Valve Adjusting Shim Selection Chart (Celica 1.8L 2ZZ-GE)
G00025381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Exhaust Valve Adjusting Shim Selection Chart (Celica 1.8L 2ZZ-GE)
G00025385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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