Valve Clearance (2AZ-FE): Adjustment

1. Remove the bolt and disconnect the engine wire harness clamp.
2. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.

Fig 1: Removing Cylinder Head Cover

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1. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
2. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the bearing cap No. 1 and No. 2 as shown in the illustration.

HINT:

Inspect and adjust the valve clearance when the engine is cold.

Fig 2: Aligning Timing Marks Of Camshaft Timing Gear With Timing Marks Of Bearing Cap No 1 And No 2

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1. Check only the valve indicated on the left.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   2. Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.
   Fig 3: Setting Cylinder No 1 To TDC/Compression Position

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   Valve clearance (Cold): 

   VALVE CLEARANCE (COLD) SPECIFICATION (1 OF 2)
   
   

   Item	Specified Condition
   Intake	0.19 to 0.29 mm (0.008 to 0.011 in.)
   Exhaust	0.30 to 0.40 mm (0.012 to 0.016 in.)

2. Turn the crankshaft clockwise 1 revolution (360°) and set the No.4 cylinder to TDC/compression.
3. Check only the valve indicated on the left.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   2. Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

Valve clearance (Cold): 

Fig 4: Setting Cylinder No 4 To TDC/Compression Position

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1. Turn the crankshaft clockwise 1 revolution (360°) and set the No. 1 cylinder to the TDC/compression.
2. Place paint marks on the timing chain and camshaft timing gear sprocket.
   Fig 5: Placing Paint Marks On Timing Chain And Camshaft Timing Gear Sprocket

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3. Remove the 2 bolts and chain tensioner.
   Fig 6: Removing Chain Tensioner

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4. Remove the No. 2 camshaft.
   1. Fix the camshaft with a wrench and then loosen the sprocket bolt.
      NOTE: Be careful not to damage the valve lifter.
      Fig 7: Removing Sprocket Bolt

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   2. Uniformly loosen and remove the No. 2 camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps.
      Fig 8: Identifying Removal Sequence Of No 2 Camshaft Bearing Cap Bolts

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   3. Raise the No. 2 camshaft and remove it. Then remove the sprocket bolt.
   4. Remove the camshaft timing sprocket and the timing chain from the No. 2 camshaft.
   5. Remove the camshaft timing sprocket from the timing chain.
   Fig 9: Removing Camshaft Timing Sprocket From Timing Chain

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5. Remove the camshaft.
   1. Uniformly loosen and remove the camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps.
   2. Remove the camshaft.
   Fig 10: Identifying Removal Sequence Of Camshaft Bearing Cap Bolts

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6. Tie the timing chain with a string.
   NOTE: Be careful not to drop anything inside the timing chain cover.
7. Remove the valve lifters.
   Fig 11: [Tie Timing Chain With String]

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8. Adjust the valve clearance.
   1. Using a micrometer, measure the thickness of the removed lifter.
   2. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
      VALVE LIFTER THICKNESS NUMBER
      
      

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

      Valve clearance: 

      VALVE CLEARANCE SPECIFICATION
      
      

      Item	Specified Condition
      Intake	A = B + (C - 0.24 mm (0.0094 in))
      Exhaust	A = B + (C- 0.35 mm (0.0138 in))

      Fig 12: Measuring Thickness Of Removed Lifter

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      EXAMPLE: (Intake)

      Measured valve clearance = 0.44 mm (0.0173 in.)

      0.44 mm (0.0173 in.) - 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.)

      (Measured - Specification = Excess clearance)

      Used shim measurement = 5.30 mm (0.2087 in.)

      0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)

      (Excess clearance + Used shim = Ideal new shim)

      Closest new shim = 5.50 mm (0.2165 in.) = Shim No. "50"

   3. Select a new lifter with a thickness as close as possible to the calculated values.

   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 valve lifter selection chart on the following 2 pages.
   Fig 13: Valve Lifter Selection Chart (Intake)

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   Fig 14: Valve Lifter Selection Chart (Exhaust)

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9. Install the camshaft.
   1. Install the timing chain on the camshaft timing gear, with the paint mark aligned with the timing marks on the camshaft timing gear.
      Fig 15: Aligning Timing Chain Paint Mark With Timing Marks On Camshaft Timing Gear

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   2. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
   1. Torque: 
   2. 30 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 
   3. 9.0 N.m (92 kgf.cm, 80 in..lbf) for bearing cap No. 3 
   Fig 16: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts

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10. Install the No. 2 camshaft.
    1. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.
       Fig 17: Aligning Paint Mark Of Timing Chain With Timing Mark On Camshaft Timing Sprocket

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    2. Raise the No. 2 camshaft and temporarily tighten the sprocket bolt.
       Fig 18: Tightening Sprocket Bolt

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    3. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
       1. Torque: 
       2. 30 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 2 
       3. 9.0 N.m (92 kgf.cm, 80 in..lbf) for bearing cap No. 3 
       Fig 19: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts

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    4. Fix the camshaft with a wrench, then tighten the sprocket bolt.
    1. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 
    NOTE: Be careful not to damage the valve lifter.
    Fig 20: Tightening Sprocket Bolt

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11. Check that the timing chain paint marks are aligned with the camshaft timing sprocket timing mark and the camshaft timing gear timing mark. Also check the alignment of the pulley groove and chain cover timing mark.
    Fig 21: Aligning Timing Chain Paint Marks With Camshaft Timing Sprocket Timing Mark And Camshaft Timing Gear Timing Mark

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12. Install the chain tensioner.
    1. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
       Fig 22: Pushing In Plunger And Applying Hook To Pin

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    2. Install a new gasket and the chain tensioner with the 2 nuts.
       1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
       NOTE: When installing the tensioner, set the hook again if the hook releases the plunger.
       Fig 23: Installing Chain Tensioner

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    3. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
       Fig 24: Turning Crankshaft Counterclockwise And Disconnecting Plunger Knock Pin From Hook

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    4. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

1. Remove any old packing (FIPG) material.
   Fig 25: Turning Crankshaft Clockwise And Checking That Slipper Pushed By Plunger

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2. Apply seal packing to 2 locations as shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 5 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing the cylinder head cover.
   Fig 26: [Applying Seal Packing]

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3. Install the cylinder head cover with the 8 bolts and 2 nuts.
   1. Torque: 
   2. 11 N.m (112 kgf.cm, 8 ft.lbf) for nut 
   3. 11 N.m (112 kgf.cm, 8 ft.lbf) for bolt A 
   4. 14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 

Fig 27: Installing Cylinder Head Cover

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1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)