Valve Clearance: Adjustments

2AZ-FE ENGINE MECHANICAL: VALVE CLEARANCE:

ADJUSTMENT

1. ADJUST VALVE CLEARANCE





(a) Turn the crankshaft clockwise 1 revolution (360°) and set the No.1 cylinder to the TDC/compression.
(b) Place paint marks on the timing chain and camshaft timing gear/sprocket.





(c) Remove the 2 bolts and chain tensioner.

NOTE: Be sure not to turn the crankshaft without the chain tensioner.

(d) Remove the No.2 camshaft.





(1) Secure the camshaft with a wrench and then loosen the sprocket bolt.

NOTE: Be careful not to damage the valve lifter.





(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.





(3) With the No. 2 camshaft in a raised position, remove the camshaft timing sprocket bolt.
(4) Remove the No. 2 camshaft and camshaft timing sprocket from the cylinder head and timing chain.





(e) 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.





(f) Tie the timing chain with a string.

NOTE: Be careful not to drop anything inside the timing chain cover.

(g) Remove the valve lifters.





(h) 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 range.





Valve clearance:





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.

(i) Valve lifter selection chart (intake).





New Lifter Thickness





Intake valve clearance (Cold):
0.19 to 0.29 mm (0.007 to 0.011 in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter was 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.
(j) Valve lifter selection chart (exhaust).





New Lifter Thickness





Exhaust valve clearance (Cold):
0.38 to 0.48 mm (0.015 to 0.019 in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter was 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.44 lifter.
(k) 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.





(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.
Bearing cap No.1 - Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
Bearing cap No.3 - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(l) Install the No.2 camshaft.





(1) Align the paint mark on the chain with the timing mark on the camshaft timing sprocket.





(2) With the No.2 camshaft in a raised position, temporarily tighten the camshaft timing sprocket bolt and install the camshaft.





(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.
Bearing cap No.2 - Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
Bearing cap No.3 - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)





(4) Secure the camshaft with a wrench, then tighten the sprocket bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTE: Be careful not to damage the valve lifter.





(m) Check that the timing chain paint marks are aligned with the camshaft timing sprocket timing marks and the camshaft timing gear timing mark. Also check the alignment of the pulley groove and chain cover timing mark 0.
(n) Install the chain tensioner.





(1) Raise the ratchet pawl, fully push in the plunger and latch the hook to the pin so that the plunger cannot spring out.





(2) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTE: When installing the tensioner, latch the hook again if the hook releases the plunger.





(3) Turn the crankshaft counterclockwise, and unlatch the plunger knock pin from the hook.





(4) Turn the crankshaft clockwise, and check that the chain tensioner slipper is pushed by the plunger.