Valve Clearance: Adjustment

1. Turn the crankshaft pulley until its groove and the "0" timing mark of the timing chain cover are aligned.
   Fig 1: Aligning Crankshaft Pulley Groove & Timing Chain Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps.

   If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks above.

   Fig 2: Identifying Timing Marks Of Camshaft Timing Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the valves.
   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 0.29 to 0.39 mm (0.011 to 0.015 in.) 

   2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
      Fig 3: Identifying Valve Clearance (1 Of 3)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the crankshaft 240° clockwise, and check the valves.
   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 0.29 to 0.39 mm (0.011 to 0.015 in.) 

   2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
      Fig 4: Identifying Valve Clearance (2 Of 3)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the crankshaft 240° clockwise, and check the valves.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   2. Valve clearance (Cold): 

      Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) 

      Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.) 

      Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

      Fig 5: Identifying Valve Clearance (3 Of 3)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the crankshaft pulley until its groove and the "0" timing mark of the timing chain cover are aligned.
      Fig 6: Aligning Crankshaft Pulley Groove & Timing Mark "0" Of Timing Chain Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
      Fig 7: Checking Timing Marks Of Camshaft Timing Gears

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Place paint marks on the No. 1 chain links corresponding to the timing marks of the camshaft timing gears.
      Fig 8: Identifying Paint & Timing Marks

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 1 chain tensioner assembly.
3. Remove the No. 2 camshaft.
4. Remove the No. 2 chain tensioner assembly.
5. Remove the camshaft.
6. Remove the No. 4 camshaft sub-assembly.
7. Remove the No. 3 chain tensioner assembly.
8. Remove the No. 3 camshaft sub-assembly.
9. Remove the valve lifters.
10. Determine the replacement valve lifter size according to the following formulas and tables:
    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.

       T: 

       Thickness of removed lifter 

       A: 

       Measured valve clearance 

       N: 

       Thickness of new lifter 

       Intake: 

       N = T + (A - 0.20 mm (0.008 in.)) 

       Exhaust: 

       N = T + (A - 0.34 mm (0.013 in.)) 

       Fig 9: Measuring Thickness Of Removed Lifter Using Micrometer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select a new lifter with a thickness as close as possible to the calculated value.

       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.).

       Fig 10: Identifying Valve Lifter Selection Table (Intake) (1 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 11: Identifying Valve Lifter Selection Table (Intake) (2 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       New lifter thickness [mm (in.)]

       THICKNESS TABLE
       
       

       Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
       06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
       08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
       10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
       12	5.120 (0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
       14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
       16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
       18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
       20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
       22	5.220 (0.2055)	46	5.460 (0.2150)	70	5.700 (0.2244)
       24	5.240 (0.2063)	48	5.480 (0.2157)	72	5.720 (0.2252)
       26	5.260 (0.2071)	50	5.500 (0.2165)	74	5.740 (0.2260)
       28	5.280 (0.2079)	52	5.520 (0.2173)

11. Install the No. 3 camshaft sub-assembly.
12. Install the No. 3 chain tensioner assembly.
13. Install the No. 4 camshaft sub-assembly.
14. Install the camshaft.
15. Install the No. 2 chain tensioner assembly.
16. Install the No. 2 camshaft.
17. Install the No. 1 chain tensioner assembly.
    1. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap.
       Fig 12: Identifying Timing Marks Of Camshaft Timing Gears

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)