Valve Clearance: Adjustments

2AZ-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT

VALVE CLEARANCE: ADJUSTMENT

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 ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE FRONT FENDER APRON SEAL RH
6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Removal
7. REMOVE FAN AND GENERATOR V BELT Removal
8. REMOVE VANE PUMP ASSEMBLY
9. REMOVE ENGINE MOUNTING INSULATOR RH Removal
10. REMOVE IGNITION COIL ASSEMBLY Removal
11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
13. CHECK VALVE CLEARANCE

(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard valve clearance (cold):

(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.
(b) Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.

(c) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard valve clearance (cold):

(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
14. ADJUST VALVE CLEARANCE
(a) Remove the No. 2 camshaft Removal.
(b) Remove the camshaft Removal.
(c) Remove the valve lifters.

(d) Using a micrometer, measure the thickness of the removed valve lifters.
(e) Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.
New lifter thickness:

EXAMPLE (Intake):
Measured intake valve clearance = 0.40 mm (0.0158 in.)
0.40 mm (0.0158 in.) - 0.24 mm (0.0094 in.) = 0.16 mm (0.0063 in.)
(Measured - Specification = Excess clearance)
Used lifter measurement = 5.250 mm (0.2067 in.)
0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.)
(Excess clearance + Used lifter = Ideal new lifter)
Closest new lifter = 5.410 mm (0.2130 in.)
Select No. 42 lifter
(f) 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.).

(g) Install the selected valve lifter.

New Lifter Thickness

Standard 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 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.

New Lifter Thickness

Standard 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 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. 4 lifter.
15. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.

(b) 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 in the illustration.

(c) Examine the front marks and numbers and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(e) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
16. INSTALL NO. 2 CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b) Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark in the camshaft timing sprocket.

(d) Examine the front marks and numbers and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(f) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(g) While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTICE: Be careful not to damage the valve lifter.

(h) Check that the paint marks on the chain and camshaft timing gear and sprocket are aligned. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.
17. INSTALL NO. 1 CHAIN TENSIONER

(a) 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.

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.

(d) Turn the crankshaft clockwise, then check that the plunger is extended.
18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
19. INSTALL IGNITION COIL ASSEMBLY Installation
20. INSTALL ENGINE MOUNTING INSULATOR RH Installation
21. INSTALL VANE PUMP ASSEMBLY
22. INSTALL FAN AND GENERATOR V BELT Installation
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
24. INSPECT FOR OIL LEAK
25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
26. INSTALL FRONT FENDER APRON SEAL RH
27. INSTALL ENGINE UNDER COVER LH
28. INSTALL ENGINE UNDER COVER RH
29. INSTALL FRONT WHEEL RH
30. PERFORM INITIALIZATION
(a) Perform initialization Testing and Inspection.
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.