Valve Clearance: Adjustment

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DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE ENGINE UNDER COVER RH
REMOVE CYLINDER HEAD COVER NO. 2 REMOVAL
REMOVE IGNITION COIL NO. 1 REMOVAL
DISCONNECT VENTILATION HOSE (See REMOVAL )
DISCONNECT VENTILATION HOSE NO. 2 (See REMOVAL )
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See REMOVAL )
INSPECT VALVE CLEARANCE
HINT:

Inspect the valve clearance when the engine is cold.
1. Set the No. 1 cylinder to TDC/compression.
  1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
    
    Fig 1: Identifying Timing Notch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration.
    HINT:
    
    If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
    
    Fig 2: Identifying Timing Marks
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valves indicated in the illustration.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (cold):
    
    for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.)
    
    Fig 3: Identifying Valve Lifter And Camshaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
3. Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "0" of the oil pump.
4. Check the valves indicated in the illustration.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (cold):
    
    for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    for exhaust: 0.25 to0.35 mm (0.010 to 0.014 in.)
  2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
    
    Fig 4: Identifying Valve Lifter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST VALVE CLEARANCE

NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves.

Remove the fan and generator V belt (See REMOVAL ).

Fig 5: Identifying Matchmark Of Timing Chain Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the engine mounting insulator sub-assembly RH (See REMOVAL ).
Set the No. 1 cylinder to TDC/compression.
1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
  
  Fig 6: Identifying Timing Notch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration.
  HINT:
  
  If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
  
  Fig 7: Identifying Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Place paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.

Fig 8: Identifying Paint Marks And Timing Marks Of Camshaft Timing Sprocket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using an 8 mm hexagon wrench, remove the screw plug.

Fig 9: Locating Screw Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

Fig 10: Identifying Stopper Plate Of Chain Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner.

Fig 11: Pushing In Plunger Of Chain Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.
HINT:
- Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
- Hold the bar with tape so that the bar does not come off.
  
  Fig 12: Rotating Camshaft Right And Left
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the fringe bolt.

Fig 13: Locating Fringe Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
NOTE: Loosen each bolt uniformly while keeping the camshaft level.

Fig 14: Identifying Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the fringe bolt and remove the camshaft timing sprocket.

Fig 15: Identifying Fringe Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove camshaft No. 2.

Fig 16: Identifying Camshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2.
NOTE: Loosen each bolt uniformly while keeping the camshaft level.

Fig 17: Identifying Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Hold the chain by hand and remove the camshaft and the camshaft timing gear assembly.

Fig 18: Identifying Camshaft And Camshaft Timing Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tie the chain with a piece of string as shown in the illustration.
Remove the 16 valve lifters.

Fig 19: Identifying Tie Chain With Piece Of String
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the thickness of the removed lifter.

Calculate the thickness of a new lifter so that the valve clearance comes to within the specified values.

Fig 20: Measuring Thickness Of Lifter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

LIFTER SPECIFICATIONS CHART

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

Valve clearance: Intake A = B + (C - 0.20 mm (0.008 in.))

Exhaust A = B + (C - 0.30 mm (0.012 in.))

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

HINT:

Lifters are available in 35 sizes in increments of 0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

Fig 21: Lifter Reference Chart (1 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Intake valve clearance (cold): 0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE:

A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.

New Shim Thickness

SHIM THICKNESS SPECIFICATIONS

Shim No.	Thickness	Shim No.	Thickness	Shim 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)

Fig 22: Lifter Reference Chart (2 Of 2)

Exhaust valve clearance (Cold): 0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE:

A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.

New Shim Thickness

SHIM THICKNESS SPECIFICATIONS

Shim No.	Thickness	Shim No.	Thickness	Shim 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)

Install the selected valve lifter.
Apply a light coat of engine oil to the camshaft and camshaft journals.
Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.

Fig 23: Identifying Chain Onto Camshaft Timing Gear With Paint Mark And Timing Mark
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.
Torque: 13 N*m (129 kgf*cm, 9.4 ft.lbf)

NOTE: Tighten each bolt uniformly while keeping the camshaft level.

Fig 24: Identifying Numbers On Camshaft Bearing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Hold the chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.
Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.

Fig 26: Identifying Timing Mark On Camshaft Timing Sprocket With Paint Mark
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

(aa) Provisionally install the flange bolt.

Fig 27: Identifying Fringe Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
(ab) Examine the front marks and the numbers of camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps, in the sequence shown in the illustration.
Torque: for bearing cap No. 2

13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf)

NOTE: Tighten each bolt uniformly while keeping the camshaft level.

Fig 28: Identifying Front Marks And Numbers Of Camshaft Bearing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
(ac) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST 09023-38400
(ad) Remove the bar from the timing chain tensioner.

Fig 29: Identifying Bar From Timing Chain Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
(ae) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.

Fig 30: Identifying Timing Notch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
(af) Check that all the pairs of timing marks are aligned.
(ag) Apply adhesive to the 2 or 3 threads of the screw plug.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Fig 31: Identifying Paint Marks And Timing Marks Of Camshaft Timing Sprocket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
(ah) Using an 8 mm hexagon wrench, install the screw plug.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
(ai) Install the engine mounting insulator sub-assembly RH (See INSTALLATION ). (for Hatchback)
(aj) Install the engine mounting insulator sub-assembly RH (See INSTALLATION ). (for Sedan)
(ak) Install the fan and generator V belt (See INSTALLATION ).
(al) Adjust the fan and generator V belt (See INSTALLATION ).
(am) Inspect the fan and generator V belt (See INSPECTION ).

Fig 32: Locating Screw Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See INSTALLATION )
CONNECT VENTILATION HOSE NO. 2 (See INSTALLATION )
CONNECT VENTILATION HOSE (See INSTALLATION )
INSTALL IGNITION COIL NO. 1 (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
CHECK FOR ENGINE OIL LEAKAGE
INSTALL CYLINDER HEAD COVER NO. 2 INSTALLATION
INSTALL ENGINE UNDER COVER RH