Trung tâm kỹ thuật ô tô Mỹ Đình THC

TRUNG TÂM KỸ THUẬT Ô TÔ MỸ ĐÌNH THC

TRUNG TÂM KỸ THUẬT
Ô TÔ MỸ ĐÌNH THC

OTOMYDINHTHC.COM

VALVE CLEARANCE: ADJUSTMENT & CHART

1.REMOVE ENGINE UNDER COVER RH

a. Remove the 2 screws and 2 bolts and remove the engine under cover RH.

2.REMOVE NO. 2 CYLINDER HEAD COVER

A143278

a. Remove the 4 nuts and No. 2 cylinder head cover.

3.REMOVE NO. 1 IGNITION COIL

A115484

a. Disconnect the 4 ignition coil connectors.

b.
A115485
Remove the 4 bolts and 4 ignition coils.

4.DISCONNECT VENTILATION HOSE

A115488

a. Disconnect the No. 2 ventilation hose.

5.DISCONNECT NO. 2 VENTILATION HOSE

A115488

a. Disconnect the No. 2 ventilation hose.

6.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

A115489

a. Disconnect the fuel injector connectors.

b.A115490

Disconnect the connector and 3 wire harness clamps shown in the illustration and disconnect the engine wire harness.

c.A115491
Remove the bolt and remove the wire harness bracket.

d.A066472E01
Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.

7.INSPECT VALVE CLEARANCE

HINT:Inspect the valve clearance when the engine is cold.

a. Set the No. 1 cylinder to TDC/compression.

i.A116203E01
Turn the crankshaft damper and align its timing notch with the timing mark “0” of the oil pump.

ii.A116204E01
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.

b.A116201
Check the valves indicated in the illustration.

i. 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.)

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

c. Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark “0” of the oil pump.

d.A116202
Check the valves indicated in the illustration.

i. 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.)

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

8.ADJUST VALVE CLEARANCE

A116206E02

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

a. Remove the fan and generator V belt (Click here).

b. Remove the engine mounting insulator sub-assembly RH (Click here).

c. Set the No. 1 cylinder to TDC/compression.

i.A116203E01
Turn the crankshaft damper and align its timing notch with the timing mark “0” of the oil pump.

ii.A116204E01
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.

d.A116207E01
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.

e.G100163
Using an 8 mm (0.31 in.) hexagon wrench, remove the screw plug.

f.A116209E01
Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

g.A116210E01
Using a wrench, rotate the No. 2 camshaft clockwise to push in the plunger of the chain tensioner.

h.A116212
Remove the screwdriver from the service hole, then align the hole of 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 out.

i.A116213
Using a wrench, hold the hexagonal lobe of the No. 2 camshaft and remove the fringe bolt.

j.A116214E01
Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 1 and No. 2 camshaft bearing caps.

NOTICE:Loosen each bolt uniformly while keeping the camshaft level.

k.
A116215
Remove the fringe bolt and remove the camshaft timing sprocket.

l.A116216
Remove the No. 2 camshaft.

m.A116217E01
Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 2 camshaft bearing cap.

NOTICE:Loosen each bolt uniformly while keeping the camshaft level.

n.A116218
Hold the chain by hand and remove the camshaft and the camshaft timing gear assembly.

o.A035227E01
Tie the chain with a piece of string as shown in the illustration.

p. Remove the 16 valve lifters.

q.A001082
Using a micrometer, measure the thickness of the removed lifter.

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

AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance

Valve clearance:Intake A = B + (C – 0.20 mm (0.008 in.))
Exhaust A = B + (C – 0.30 mm (0.012 in))

s. 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.).

A117457

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 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)
A117458

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 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)

 

t. Install the selected valve lifter.

 

u. Apply a light coat of engine oil to the camshaft and camshaft journals.

 

v.
A116220E01

Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.

 

w.
A116222E01

Examine the front marks and the numbers on the No. 2 camshaft bearing cap and check that the order 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 ft.*lbf}

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

 

x.
A116216

Install the No. 2 camshaft.

 

y.
A116224E01

Hold the chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.

 

z. Align the pin hole in the camshaft timing sprocket with the pin of the camshaft, and install the sprocket onto the camshaft.

 

aa.
A116215

Provisionally install the fringe bolt.

 

ab.
A116223E02

Examine the front marks and the numbers of the No. 1 and No. 2 camshaft bearing caps and check that the order 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 ft.*lbf}for No. 2 bearing cap23 N*m{235 kgf*cm, 17 ft.*lbf}for No. 1 bearing cap

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

 

ac.
A116225

Using a union nut wrench, hold the hexagonal lobe of No. 2 camshaft and install the fringe bolt.

 

Torque: 64 N*m{653 kgf*cm, 47 ft.*lbf}for use without union nut wrench59 N*m{602 kgf*cm, 44 ft.*lbf}for use with union nut wrench

HINT:•This torque value can be obtained by using a torque wrench with a fulcrum length of 300mm (11.8 in.) and a union nut wrench with a fulcrum length of 25mm (0.984 in.) (Click here).

•This torque value is effective when the union nut wrench is parallel to the torque wrench.

 

 

ad. Remove the bar from the timing chain tensioner.

 

ae.
A116203E01

Turn the crankshaft damper and align its timing notch with the timing mark “0” of the oil pump.

 

af.
A116207E01

Check that all the pairs of timing marks are aligned.

 

ag. Apply adhesive to the end 2 or 3 threads of the screw plug.

 

Adhesive:Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

 

 

ah.
G100163

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 (Click here).

 

aj. Install the fan and generator V belt (Click here).

 

ak. Adjust the fan and generator V belt (Click here).

 

al. Inspect the fan and generator V belt (Click here).

 

9.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

A115503E01

a. Apply seal packing to the cylinder head as shown in the illustration.

 

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

 

NOTICE:•Remove any oil from the contact surface.

•Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing.

•Do not start the engine for at least 2 hours after the installation.

 

 

b. Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

 

c.
A035756E01

Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

 

Torque: 10 N*m{102 kgf*cm, 7.0 ft.*lbf}

 

d.
A115491

Install the wire harness bracket with the bolt.

 

Torque: 13 N*m{133 kgf*cm, 10 ft.*lbf}

 

e.
A115490

Connect the connector and 3 wire harness clamps shown in the illustration and connect the engine wire harness.

 

f.
A115489

Connect the fuel injector connectors.

 

10.CONNECT NO. 2 VENTILATION HOSE

A115488

a. Connect No. 2 ventilation hose.

 

11.CONNECT VENTILATION HOSE

A115487

a. Connect the ventilation hose.

 

12.INSTALL NO. 1 IGNITION COIL

A115485

a. Install the 4 ignition coils with the 4 bolts.

 

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

 

b.
A115484

Connect the 4 ignition coil connectors.

 

13.INSPECT FOR OIL LEAK

14.INSTALL NO. 2 CYLINDER HEAD COVER

A143278E01

a. Tighten the 2 A nuts, then the 2 B nuts.

 

Torque: 7.0 N*m{71 kgf*cm, 62 in.*lbf}

 

15.INSTALL ENGINE UNDER COVER RH

a. Install the engine under cover RH with the 2 screws and 2 bolts.

 

Torque: 5.0 N*m{51 kgf*cm, 44 in.*lbf}for bolt