Valve Clearance (For Sedan) Adjustment

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

Disconnect the 4 ignition coil connectors.

Remove the 4 bolts and 4 ignition coils.

Disconnect the ventilation hose.

Disconnect fuel vapor feed hose assembly.

Disconnect the fuel injector connectors.

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

Remove the bolt and remove the wire harness bracket.

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

Remove the gasket from the cylinder head cover sub-assembly.

Set the No. 1 cylinder to TDC/compression.

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





2. 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.

Check the valves indicated in the illustration.

1. 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.)
   

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

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

Check the valves indicated in the illustration.

1. 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.)
   

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

Remove the fan and generator V belt (YARIS_NCP93 RM000001DCJ016X_01_0002.html).

Remove the engine mounting insulator sub-assembly RH (YARIS_NCP93 RM000001DDZ00QX_01_0037.html).

Set the No. 1 cylinder to TDC/compression.

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





2. 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.

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.

Using an 8 mm hexagon wrench, remove the screw plug.

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

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

Remove the screwdriver from the service hole, then align the hole in 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:

1. Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
   
2. Hold the bar with tape so that the bar does not come off.
   

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

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

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Remove the fringe bolt and remove the camshaft timing sprocket.

Remove No. 2 camshaft.

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

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

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

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

Remove the 16 valve lifters.

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

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

Valve clearance:

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

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

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.).

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)

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)

Install the selected valve lifter.

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

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

Examine the front marks and the numbers on No. 2 camshaft bearing cap and check that the sequence 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.

Install No. 2 camshaft.

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

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

Provisionally install the flange bolt.

Examine the front marks and the numbers of No. 1 camshaft bearing cap and No. 2 camshaft bearing cap and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps, in the sequence shown in the illustration.

Torque:

for No. 2 bearing cap:

13 N*m{129 kgf*cm, 9 ft.*lbf}

for No. 1 bearing cap:

23 N*m{235 kgf*cm, 17 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

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

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Remove the bar from the timing chain tensioner.

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

Check that all the pairs of timing marks are aligned.

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Using an 8 mm hexagon wrench, install the screw plug.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Install the engine mounting insulator sub-assembly RH (YARIS_NCP93 RM000001DDV00RX_01_0047.html).

Install the fan and generator V belt (YARIS_NCP93 RM000001DCG017X_01_0001.html).

Adjust the fan and generator V belt (YARIS_NCP93 RM000001DCG017X_01_0002.html).

Inspect the fan and generator V belt (YARIS_NCP93 RM000001DCH00ZX_01_0001.html).

Install a new gasket to the cylinder head cover sub-assembly.

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:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing.
   
3. Do not start the engine for at least 2 hours after the installation.
   

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

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}

Install the wire harness bracket with the bolt.

Torque:

13 N*m{133 kgf*cm, 9.6 ft.*lbf}

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

Connect the fuel injector connectors.

Connect fuel vapor feed hose assembly.

Connect the ventilation hose.

Install the 4 ignition coils with the 4 bolts.

Torque:

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

NOTICE:

If the body or cap of the ignition coil is dropped or subjected to a strong impact, replace the ignition coil with a new one.

Connect the 4 ignition coil connectors.

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

Torque:

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