Valve Clearance: Adjustments

2AZ-FXE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT

ADJUSTMENT

1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FRONT FENDER APRON SUB-ASSEMBLY RH
5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Removal
6. REMOVE IGNITION COIL ASSEMBLY Removal
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
8. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b) Check that each timing mark of 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 by 1 revolution (360°) to align the timing marks as above.
9. 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 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.
10. 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 range.
New lifter thickness:

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

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

(g) Valve lifter selection chart (intake).

New lifter thickness

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.
(h) Valve lifter selection chart (exhaust).

New lifter thickness

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.
(i) Install the selected valve lifter.
11. 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 on 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 to 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.
No. 1 bearing cap - Torque: 30 Nm (301 kgf-cm, 22ft-lbf)
No. 1 bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
12. 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 on 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.
No. 2 bearing cap - Torque: 30 Nm (301 kgf-cm, 22ft-lbf)
No. 2 bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)

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

(h) 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.
13. INSTALL NO. 1 CHAIN TENSIONER Installation
14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
15. INSTALL IGNITION COIL ASSEMBLY Installation
16. CHECK FOR ENGINE OIL LEAKS
17. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
18. INSTALL FRONT FENDER APRON RH
19. INSTALL ENGINE UNDER COVER LH
20. INSTALL ENGINE UNDER COVER RH
21. INSTALL FRONT WHEEL RH