Valve Clearance Adjustment

Remove the 2 nuts and cover.

Disconnect the 4 ignition coil connectors.

Remove the 4 bolts and 4 ignition coils.

Disconnect the 2 ventilation hoses from the cylinder head cover.

Remove the 2 bolts and disconnect the 2 engine wires.

Remove the 8 bolts, 2 nuts and cylinder head cover.

Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.

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.

Check only the valves indicated.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard valve clearance (cold):

   Item	Standard Condition
   Intake	0.21 to 0.27 mm (0.0083 to 0.0106 in.)
   Exhaust	0.30 to 0.40 mm (0.0118 to 0.0157 in.)

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

Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.

Check only the valves indicated.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard valve clearance (cold):

   Item	Standard Condition
   Intake	0.21 to 0.27 mm (0.0083 to 0.0106 in.)
   Exhaust	0.30 to 0.40 mm (0.0118 to 0.0157 in.)

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

Remove the No. 2 camshaft (RAV4_ACA30 RM000001AN800TX_01_0057.html).

Remove the camshaft (RAV4_ACA30 RM000001AN800TX_01_0058.html).

Remove the valve lifters.

Using a micrometer, measure the thickness of the removed valve lifters.

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

New lifter thickness:

Item	Specification
Intake	A = B + (C - 0.24 mm (0.0095 in.))
Exhaust	A = B + (C - 0.35 mm (0.0138 in.))

1. Measured intake valve clearance = 0.16 mm (0.0063 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 measurement = 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.)
   
1. Select No. 42 lifter
   

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

HINT:

1. 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.).)
   


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

Valve lifter selection chart (intake).

Standard intake valve clearance (cold):

0.21 to 0.27 mm (0.0083 to 0.0106 in.)

Valve lifter selection chart (Exhaust).

Standard exhaust valve clearance (cold):

0.32 to 0.38 mm (0.0126 to 0.0150 in.)

Install the selected valve lifter.

Apply a light coat of engine oil to the journal portion of the camshaft.

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.

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.

Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque:

29.5 N*m{301 kgf*cm, 22 ft.*lbf} for No. 1 bearing cap

9.0 N*m{92 kgf*cm, 80 in.*lbf} for No. 3 bearing cap

Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

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.

While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.

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.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque:

29.5 N*m{301 kgf*cm, 22 ft.*lbf} for No. 2 bearing cap

9.0 N*m{92 kgf*cm, 80 in.*lbf} for No. 3 bearing cap

While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

NOTICE:

Be careful not to damage the valve lifter.

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.

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.

Install a new gasket and the chain tensioner with the 2 nuts.

Torque:

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

NOTICE:

When installing the chain tensioner, set the hook again if the hook releases the plunger.

Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

Turn the crankshaft clockwise, then check that the plunger is extended.

Remove any old packing material from the contact surface.

Apply seal packing to the 2 locations shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

1. Remove any oil from the contact surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the cylinder head cover with the 8 bolts and 2 nuts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf} for bolt A

14 N*m{143 kgf*cm, 10 ft.*lbf} for bolt B

11 N*m{112 kgf*cm, 8 ft.*lbf} for nut

Install the 2 engine wires with the 2 bolts.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the 2 ventilation hoses to the cylinder head cover.

Install the 4 ignition coils with the 4 bolts.

Torque:

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

Connect the 4 ignition coil connectors.

Start the engine, and check that there are no oil leaks.

Install the engine cover with the 2 nuts.

Torque:

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