LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2008 >> FJ Cruiser RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 156 (Engine Mechanical (2AZ-FE)) >> Valve Clearance >> Adjustment

Valve Clearance: Adjustment

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  2. REMOVE FRONT WHEEL RH 
  3. REMOVE NO. 1 ENGINE UNDER COVER 
  4. REMOVE FRONT FENDER APRON RH 
  5. REMOVE NO. 1 ENGINE COVER (see appropriate step(s) under  REMOVAL  ) 
  6. REMOVE IGNITION COIL ASSEMBLY (see  REMOVAL  ) 
  7. REMOVE SPARK PLUG 
    1. Remove the 4 spark plugs.
  8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  9. SET NO. 1 CYLINDER TO TDC/COMPRESSION (see appropriate step(s) under  REMOVAL  ) 
  10. CHECK VALVE CLEARANCE 
    1. Check only the valves indicated.
      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (cold) 

        STANDARD VALVE CLEARANCE (COLD)

        Item Standard Condition
        Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
        Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.)
        Fig 1: Measuring Clearance Between Valve Lifter And Camshaft
        G04484594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.
    2. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.
    3. Check only the valves indicated.
      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (cold) 

        STANDARD VALVE CLEARANCE (COLD)

        Item Standard Condition
        Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
        Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.)
        Fig 2: Measuring Clearance Between Valve Lifter And Camshaft
        G04484595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
  11. ADJUST VALVE CLEARANCE 
    1. Remove the No. 2 camshaft (see appropriate step(s) under REMOVAL ).
    2. Remove the camshaft (see appropriate step(s) under REMOVAL ).
    3. Remove the valve lifters.
    4. Using a micrometer, measure the thickness of the removed valve lifters.
    5. Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.

      New lifter thickness 

      LIFTER THICKNESS SPECIFICATION

      Item Specification
      Intake A = B + (C - 0.24 mm (0.0095 in.))
      Exhaust A = B + (C - 0.43 mm (0.0169 in.))
      A New lifter thickness
      B Used lifter thickness
      C Measured valve clearance
      Fig 3: Measuring Thickness Of Valve Lifter
      G04484596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      CALCULATION EXAMPLE (Intake):

      1. Measured intake valve clearance = 0.40 mm (0.0158 in.)

        (Measured - Specification = Excess clearance)

        1. 0.40 mm (0.0158 in.) - 0.24 mm (0.0095 in.) = 0.16 mm (0.0063 in.)
      2. Measured used lifter thickness = 5.250 mm (0.2067 in.)
      3. New lifter thickness = 5.410 mm (0.2130 in.)

        (Excess clearance + Used lifter thickness = Ideal new lifter)

        1. 0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.)
      4. Closest new lifter = 5.420 mm (0.2134 in.)
        • Select No. 42 lifter
    6. 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 to 5.740 mm (0.1992 to 0.2260 in.).
      • The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 in.)
        Fig 4: Identifying Identification Number Inside Valve Lifters
        G04484597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Valve lifter selection chart (intake).
      Fig 5: Identifying Valve Lifter Selection Chart (Intake)
      G04484598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      New lifter thickness 

      NEW LIFTER THICKNESS SPECIFICATION (INTAKE)

      Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.)
      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) - -

      Standard intake valve clearance (cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) 

      EXAMPLE:

      The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.).

      Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter.

    8. Valve lifter selection chart (exhaust).
      Fig 6: Identifying Valve Lifter Selection Chart (Exhaust)
      G04484599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      New lifter thickness 

      NEW LIFTER THICKNESS SPECIFICATION (EXHAUST)

      Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.)
      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) - -

      Standard exhaust valve clearance (cold): 0.38 to 0.48 mm (0.0150 to 0.0189 in.) 

      EXAMPLE:

      The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.430 mm (0.0169 in.).

      Replace the 5.340 mm (0.2102 in.) lifter with a new No. 42 lifter.

    9. Install the selected valve lifter.
  12. INSTALL CAMSHAFT 
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
    2. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark in the camshaft timing gear as shown.
      Fig 7: Aligning Paint Mark With Timing Mark In Camshaft Timing Gear
      G04484600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Examine the front marks and numbers, and check that the order is as shown. Then install the bearing caps into the cylinder head.
      Fig 8: Identifying Bearing Cap Numbers
      G04484601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
    5. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the figure below.

      Torque: 

      29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No. 1 bearing cap 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3 bearing cap 

      Fig 9: Tighting Bearing Cap Bolts In Sequence
      G04484602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 CAMSHAFT 
    1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.
    2. 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 10: Aligning With Timing Mark On Camshaft Timing Sprocket
      G04484603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.
      Fig 11: Tighting Camshaft Timing Sprocket Set Bolt
      G04484604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Examine the front marks and numbers, and check that the order is as shown in the figure below. Then install the bearing caps onto the cylinder head.
      5. Fig 12: Installing Bearing Caps Onto Cylinder Head
      G04484605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
    6. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the figure below.

      Torque: 

      29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No. 2 bearing cap 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3 bearing cap 

      Fig 13: Tighting Bearing Cap Bolts In Sequence
      G04484606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      NOTE: Be careful not to damage the valve lifter.
      Fig 14: Tightening Camshaft Timing Sprocket Set Bolt
      G04484607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.
      Fig 15: Aligning With Timing Marks On Camshaft Timing Gear And Camshaft Timing Sprocket
      G04484608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 CHAIN TENSIONER 
    1. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.
      Fig 16: Identifying Plunger Position
      G04484609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and the chain tensioner with the 2 nuts.

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

      NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
      Fig 17: Installing Gasket
      G04484610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.
      Fig 18: Disconnecting Plunger Knock Pin From Hook
      G04484611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the crankshaft clockwise, then check that the plunger is extended.
      Fig 19: Checking Plunger Extended
      G04484612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  16. INSTALL SPARK PLUG 
    1. Install the 4 spark plugs.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  17. INSTALL IGNITION COIL ASSEMBLY (see  INSTALLATION  ) 
  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  19. CHECK FOR ENGINE OIL LEAKS 
  20. INSTALL NO. 1 ENGINE COVER (see appropriate step(s) under  INSTALLATION  ) 
  21. INSTALL FRONT FENDER APRON RH 
  22. INSTALL NO. 1 ENGINE UNDER COVER 
  23. INSTALL FRONT WHEEL RH 
scientia non olet · About LEMON Manuals