Valve Clearance (3MZ-FE): Adjustment

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See REPLACEMENT )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See REPLACEMENT )
REMOVE V-BANK COVER SUB-ASSY (See REPLACEMENT )
REMOVE AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
REMOVE EMISSION CONTROL VALVE SET (See REPLACEMENT )
REMOVE INTAKE AIR SURGE TANK (See REPLACEMENT )
REMOVE RADIATOR HOSE INLET
REMOVE IGNITION COIL ASSY
REMOVE CYLINDER HEAD COVER SUB-ASSY
1. Remove the 2 engine wire harness clamps.
2. Remove the 3 nuts, then disconnect the engine wire harness.
3. Remove the 9 bolts and cylinder head cover.
  
  Fig 1: Identifying Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSY LH
1. Using an E6 Torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
2. Remove the 9 bolts and cylinder head cover.
  
  Fig 2: Removing Bolts And Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE CLEARANCE
1. Turn the crankshaft pulley, then align the timing notch with the timing mark "O" of the timing belt No. 1 cover.
2. Check that the valve lifters on the intake side of the No. 1 cylinder are not pushed by the cam.
  If the valve lifters are pushed, turn the crankshaft by 1 revolution (360°) and align the marks as above.
  
  Fig 3: Aligning Timing Notch With Timing Mark Of Timing Belt Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the valve indicate in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter an camshaft.
    Valve clearance (Cold):
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
  2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
    
    Fig 4: Inspecting Valves (1 of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft by 2/3 of a revolution (240°), then inspect the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold):
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
  2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
    
    Fig 5: Inspecting Valves (2 of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the crankshaft by 2/3 of a revolution (240°), then inspect the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold):
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
  2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
    
    Fig 6: Inspecting Valves (3 of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST VALVE CLEARANCE
1. Turn the camshaft so that the cam lobe faces upward.
2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
  
  Fig 7: Adjusting Valve Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).
  SST 09248-55040 (09248-05410, 09248-05420)
  
  HINT:
  - Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
  - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent SST (B) from getting stuck, insert it gently from the intake side at a slight angle.
    
    Fig 8: Pressing Down Valve Lifter And Placing SST Between Camshaft And Valve Lifter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 9: SST Table
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a small screwdriver and magnetic finger, remove the adjusting shim.
  
  Fig 10: Removing Adjusting Shim Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a micrometer, measure the thickness of the removed shim.
6. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
  
  Fig 11: Measuring Thickness Of Shim Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 12: Thickness Specification Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Specified value (Cold):
  
  Intake A = B + (C - 0.20 mm (0.0079 in.))
  
  Exhaust A = B + (C - 0.30 mm (0.0118 in.))
7. Select a new shim with a thickness which is as close to the calculated values as possible.
  
  Fig 13: Example of Determining Thickness Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
  - Refer to following New Shim Thickness tables . See Fig 14 and Fig 15 .
    
    Fig 14: Adjusting Shim Selection Chart (Intake)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 15: Adjusting Shim Selection Chart (Exhaust)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Place a new adjusting shim on the valve lifter with the imprinted number facing down.
9. Press down the valve lifter with SST (A), then remove SST (B).
  SST 09248-55040 (09248-05410, 09248-05420)
10. Recheck the valve clearance.
  
  Fig 16: Pressing Down Valve Lifter Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSY
1. Apply seal packing to the cylinder head as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 17: Applying Seal Packing To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
2. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
  Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
3. Install the engine wire harness with the 3 nuts.
  Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSY LH
1. Apply seal packing to the cylinder head as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 18: Applying Seal Packing To Cylinder Head (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
2. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
  Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
3. Install the engine wire harness with the 3 nuts.
  Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
INSTALL IGNITION COIL ASSY Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
INSTALL INTAKE AIR SURGE TANK (See REPLACEMENT )
INSTALL EMISSION CONTROL VALVE SET (See REPLACEMENT )
INSTALL AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
CHECK CONNECTION OF VACUUM HOSE (See REPLACEMENT )
INSTALL V-BANK COVER SUB-ASSY (See REPLACEMENT )
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See REPLACEMENT )
ADD ENGINE COOLANT (See REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKS (See INSPECTION )
SYSTEM INITIALIZATION (See PRECAUTION )