VALVE CLEARANCE ADJUSTMENT


  1. REMOVE ENGINE UNDER COVER RH

  2. REMOVE IGNITION COIL ASSEMBLY


    1. A01CC5A

      Disconnect the 4 ignition coil connectors.

    2. Remove the 4 bolts and 4 ignition coils.

  3. REMOVE SPARK PLUG


    1. A01CD6B

      Remove the 4 spark plugs.

  4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CFHD

      Remove the 2 ventilation hoses from the cylinder head cover sub-assembly.

    2. A01CCE9

      Remove the 3 bolts and separate the wire harness.

    3. A01CDS4

      Disconnect the 2 wire harness clamps.

    4. A01CFXM

      Remove the 8 bolts and 2 nuts, then remove the cylinder head cover sub-assembly and gasket.

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CAPME19
      Text in Illustration
      *1 Timing Mark
      *2 Paint Mark
      *3 Groove

      Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.

    2. Check that each timing mark on the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

      If not, turn the crankshaft pulley 1 revolution (360°) to align the timing marks as illustrated.

    3. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.

  6. CHECK VALVE CLEARANCE


    1. A01CEA3E07
      Text in Illustration
      *a No. 1 Cylinder TDC/Compression
      *b Intake
      *c Exhaust

      Check only the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard Valve Clearance (Cold)
        Item Specified Condition
        Intake 0.19 to 0.29 mm (0.00748 to 0.0114 in.)
        Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.)

      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 TDC/Compression.

    3. A01CG6QE09
      Text in Illustration
      *a No. 4 Cylinder TDC/Compression
      *b Intake
      *c Exhaust

      Check only the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard Valve Clearance (Cold)
        Item Specified Condition
        Intake 0.19 to 0.29 mm (0.00748 to 0.0114 in.)
        Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.)

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

  7. ADJUST VALVE CLEARANCE


    1. Set No. 1 cylinder to TDC/compression Click here.

    2. Remove the No. 1 chain tensioner Click here.

    3. Loosen the camshaft timing sprocket Click here.

    4. Remove the No. 2 camshaft Click here.

    5. Remove the camshaft Click here.

    6. Remove the valve lifters.

    7. A01CBSEE01

      Using a micrometer, measure the thickness of the removed valve lifters.

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

      New Lifter Thickness
      Item Specification
      Intake A = B + (C - 0.24 mm (0.00945 in.))
      Exhaust A = B + (C - 0.43 mm (0.0169 in.))
      A New lifter thickness
      B Used lifter thickness
      C Measured valve clearance

      CALCULATION EXAMPLE (Intake):


      1. Measured intake valve clearance = 0.40 mm (0.0157 in.)

        (Measured - Specification = Excess clearance)


        1. 0.40 mm (0.0157 in.) - 0.24 mm (0.00945 in.) = 0.16 mm (0.00630 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 (0.00630 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

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

      Tech Tips


      • Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 to 5.740 mm (0.1992 to 0.2260 in.).

      • A01CEHGE01

        The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 in.)

    10. Valve lifter selection chart (intake).

      A01CBBNE02
      New Lifter Thickness
      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 (0.00748 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.

    11. Valve lifter selection chart (exhaust).

      A01CE28E01
      New Lifter Thickness
      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 0.510 mm (0.0201 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 42 lifter.

    12. Install the selected valve lifter.

    13. Install the camshaft Click here.

    14. Install the No. 2 camshaft Click here.

    15. Install the No. 1 chain tensioner Click here.

  8. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing material from the contact surfaces.

    2. A01CBWQE01

      Apply seal packing to the 2 locations shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the oil pan.

    3. A01CD2IE01

      Install the cylinder head cover gasket and sub-assembly with the 8 bolts and 2 nuts.

      Torque:
      Bolt A
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Nut
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    4. A01CCE9

      Install the engine wire harness with the 3 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    5. A01CDS4

      Connect the 2 wire harness clamps.

    6. A01CFHD

      Connect the 2 ventilation hoses to the cylinder head cover.

  9. INSTALL SPARK PLUG


    1. A01CF85

      Install the 4 spark plugs.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  10. INSTALL IGNITION COIL ASSEMBLY


    1. A01CC5A

      Install the 4 ignition coils with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 4 ignition coil connectors.

  11. INSPECT FOR OIL LEAK

  12. INSPECT IGNITION TIMING

    Note


    • Turn all the electrical systems and the A/C off.

    • When checking the ignition timing, the transaxle should be in neutral or park.


    1. Warm up and stop the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG).

      3. Turn the intelligent tester on.

      4. Enter the following menus: Power Train / Engine and ECT / Data List / IGN Advance

      5. Start the engine.

      6. According to the display on the intelligent tester, read the Data List.

        Standard ignition timing
        8 to 16° BTDC at idle

      7. Check that the ignition timing advances immediately when the engine speed is increased.

      8. Turn the engine switch off.

      9. Disconnect the intelligent tester from the DLC3.

    3. When not using the intelligent tester:


      1. A01CEC7

        Open the ignition cover located to the right of the No. 4 ignition coil.

      2. Pull the wire harness out from the IG cover.

      3. Connect the timing light to the wire harness.

        Note

        Use a timing light that detects the primary signal.

      4. A01CBA7E37
        Text in Illustration
        *1 DLC3

        Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST
        09843-18040

      5. Allow the engine to idle and check the ignition timing.

        Standard ignition timing
        8 to 12° BTDC at idle

        Tech Tips

        Run the engine at 1000 to 1300 rpm for 5 seconds, then check that the engine speed returns to idle speed.

      6. Disconnect SST from terminals 13 (TC) and 4 (CG) of the DLC3.

      7. Allow the engine to idle and check the ignition timing.

        Standard ignition timing
        8 to 16° BTDC at idle

      8. Check that the ignition timing advances immediately when the engine speed is increased.

      9. Turn the engine switch off.

      10. Remove the timing light.

      11. Close the IG cover.

  13. INSTALL ENGINE UNDER COVER RH