Section 49 (Engine Valve Clearance): Adjustment

WARNING: This page is about a different car, the 2004 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

DRAIN COOLANT, see REPLACEMENT .
REMOVE FRONT WIPER ARM HEAD CAP
REMOVE FR WIPER ARM RH, see REPLACEMENT .
REMOVE FR WIPER ARM LH, see REPLACEMENT .
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY, see REPLACEMENT .
REMOVE WIPER LINK ASSEMBLY, see REPLACEMENT .
REMOVE COWL TOP TO COWL BRACE INNER NO. 1, see REPLACEMENT
REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT, see REPLACEMENT
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V-BANK COVER SUB-ASSEMBLY
1. Using a socket hexagon wrench 5, remove the 3 nuts.
2. Remove the V-bank cover.
Fig 1: Removing V-Bank Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CLEANER CAP SUB-ASSEMBLY, see REPLACEMENT .
REMOVE EMISSION CONTROL VALVE SET
1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.
  
  Fig 2: Removing Wire Harness Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the fuel vapor feed hose.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 2 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts and the emission control valve set.
REMOVE INTAKE AIR SURGE TANK
1. Disconnect the throttle motor connector.
2. Disconnect the water by-pass hose No. 3.
3. Disconnect the water by-pass hose No. 2.
4. Disconnect the union to check valve hose.
5. Disconnect the ventilation hose.
  
  Fig 5: Disconnecting Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 2 set nuts of the pressure feed tube.
  
  Fig 6: Removing Set Nuts Of Pressure Feed Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 2 bolts and the engine hunger No. 1.
8. Remove the 2 bolts and the surge tank stay No. 1.
9. Remove the 2 bolts and the surge tank stay No. 2.
  
  Fig 7: Removing Bolts And Engine Hanger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a socket hexagon wrench 8, remove the 4 bolts.
11. Remove the 2 nuts, the emission control valve bracket and the intake air surge tank.
12. Remove the gasket from the intake air surge tank.
Fig 8: Removing Gasket From Intake Air Surge Tank
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RADIATOR HOSE INLET
REMOVE IGNITION COIL ASSEMBLY
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

Fig 9: Removing Cylinder Head Cover Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 engine wire harness clamps.
2. Remove the 3 nuts and disconnect the engine wire harness.
3. Remove the 9 bolts and the cylinder head cover.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

Fig 10: Removing Cylinder Head Cover Sub-Assembly LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using an E6 Torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
2. Remove the 9 bolts and the cylinder head cover.
INSPECT VALVE CLEARANCE

Fig 11: Inspecting Valve Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No. 1 timing belt cover.
2. Check that the valve lifters on the No. 1 (IN and EX) are both loose.
  If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
3. Check the valves indicated as shown.
  
  Fig 12: Measuring Clearance Between Valve Lifter And Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
    Valve clearance (Cold):
    
    Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.)
  2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
4. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated as shown.
  
  Fig 13: Measuring Clearance Between Valve Lifter And Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
    Valve clearance (Cold):
    
    Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.)
  2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
5. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated as shown.
  
  Fig 14: Measuring Clearance Between Valve Lifter And Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
    Valve clearance (Cold):
    
    Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
    
    Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.)
  2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

ADJUST VALVE CLEARANCE

Turn the camshaft so that the cam lobe is facing upward.
Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.

Fig 15: Turning Valve Lifter With A Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).

SST 09248-55040 (09248-05410, 09248-05420)

HINT:

Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown.

Fig 16: Removing Valve Lifter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle.

SPECIAL SERVICE TOOL SPECIFICATION

SST (A)	09248-05410
SST (B)	09248-05420

Using a small screwdriver and magnetic finger, remove the adjusting shim.

Fig 17: Removing Adjusting Shim
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the thickness of the removed shim.

Calculate the thickness of a new shim so the valve clearance comes within the specified value.

SHIM THICKNESS SPECIFICATION

A	Thickness of new shim
B	Thickness of used shim
C	Measured valve clearance

Fig 18: Measuring Thickness Of Shim

Specified value (Cold):

Intake A = B + (C - 0.20 mm (0.008 in.))

Exhaust A = B + (C - 0.30 mm (0.012 in.))

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

Fig 19: Select A New Shim With A Thickness As Close As Possible To Calculated Values
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:
- Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
- Refer to new shim thickness table.
Fig 20: Adjusting Shim Selection Chart (Intake)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 21: Adjusting Shim Selection Chart (Exhaust)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Place a new adjusting shim on the valve lifter, with imprinted numbers facing down.
Press down the valve lifter with SST (A), and remove SST (B).
SST 09248-55040 (09248-05410, 09248-05420)

Fig 22: Pressing Down Valve Lifter With SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Recheck the valve clearance.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Apply seal packing to the cylinder head as shown.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 23: Applying Seal Packing To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
2. Install the cylinder head cover with the 9 bolts. Tighten the bolt uniformly in several steps.
  Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
3. Install the engine wire harness with the 3 nuts.
  Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Apply seal packing to the cylinder head as shown.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 24: Applying Seal Packing To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
2. Install the cylinder head cover with the 9 bolts. Tighten the bolt uniformly in several steps.
  Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
3. Install the engine wire harness with the 3 nuts.
  Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 N.m (8.0 kgf.cm, 71 in.lbf)
INSTALL INTAKE AIR SURGE TANK
1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and the emission control valve bracket with the 2 nuts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
3. Using a socket hexagon wrench 8, tighten the 4 bolts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
4. Install the surge tank stay No. 2 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
5. Install the surge tank stay No. 1 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
6. Install the engine hunger No. 1 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
7. Install the pressure feed tube with the 2 nuts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water by-pass hose No. 2.
11. Connect the water by-pass hose No. 3.
12. Connect the throttle motor connector.
INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL AIR CLEANER CAP SUB-ASSEMBLY, see REPLACEMENT .
CONNECT VACUUM HOSE, see REPLACEMENT .
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Fit the 2 retainers and install the V-bank cover.
2. Using a socket hexagon wrench 5, tighten the 3 nuts.
  Torque: 7.9 N.m (81 kgf.cm, 70 in.lbf)
INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT, see REPLACEMENT
INSTALL COWL TOP TO COWL BRACE INNER NO. 1, see REPLACEMENT
INSTALL WIPER LINK ASSEMBLY, see REPLACEMENT .
INSTALL FR WIPER ARM LH, see REPLACEMENT .
INSTALL FR WIPER ARM RH, see REPLACEMENT .
ADD COOLANT, see REPLACEMENT .
CHECK FOR ENGINE COOLANT LEAKS, see REPLACEMENT .