14–7

ENGINE MECHANICAL – VALVE CLEARANCE

VALVE CLEARANCE
141FO–01

ADJUSTMENT

1. REMOVE CYLINDER HEAD COVER NO.2

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

A66316

2. REMOVE IGNITION COIL NO.1

(a) Remove the 4 bolts and pull out the 4 ignition coils.

A79683

3. DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose from the cylinder head
cover.

A80969

4. DISCONNECT VENTILATION HOSE NO.2

(a) Disconnect the ventilation hose No. 2 from the cylinder
head cover.

A80970

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ENGINE MECHANICAL – VALVE CLEARANCE

5. REMOVE CYLINDER HEAD COVER SUB–ASSY

(a) Remove the 9 bolts and 2 nuts, and then remove the cylin-
der head cover.
6. REMOVE ENGINE UNDER COVER RH
(See page 19–3)

A66472

7. INSPECT VALVE CLEARANCE

HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Set the No. 1 cylinder to the TDC/compression.
Timing Marks (1) Turn the crankshaft damper, and align its timing
notch with the timing mark ”0” of the chain cover.
(2) Check that both timing marks on the camshaft tim-
ing sprocket and the camshaft timing gear are fac-
A38016 ing upward as shown in the illustration.
HINT:
If not, turn the crankshaft 1 complete revolution (360) and align
the marks as above.

(b) Check the valves indicated in the illustration.

No. 1 Cylinder TDC/Compression
(1) Using a feeler gauge, measure the clearance be-
EX
tween the valve lifter and 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 the out–of–specification valve clearance
measurements. They will be used later to determine
IN A50689 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 chain
cover.

No. 4 Cylinder TDC/Compression

(d) Check the valves indicated in the illustration.
EX (1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and 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 the out–of–specification valve clearance
measurements. They will be used later to determine
IN A50690 the required replacement adjusting shim.

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ENGINE MECHANICAL – VALVE CLEARANCE

8. ADJUST VALVE CLEARANCE

Matchmark
40 NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft damper counterclockwise 40 from
the TDC and align its timing notch with the matchmark of
the timing chain cover to prevent contact of the pistons
with the valves.

A50156

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

(1) Turn the crankshaft damper, and align its timing
notch with timing mark ”0” of the chain cover.
(2) Check that both timing marks on the camshaft tim-
Timing Marks
ing sprocket and valve timing controller assembly
are facing upward as shown in the illustration.
HINT:
If not, turn the crankshaft 1 complete revolution (360) and align
A38016 the marks as above.

(b) Put paint marks on the timing chain in place where the tim-
Paint Marks
ing marks of the camshaft timing sprocket and the cam-
shaft timing gear are located.

Timing Marks
A50135

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

A37101

Hexagonal Portion (d) Insert a screwdriver into the service hole of the chain ten-
Plunger
Stopper sioner to the hole stopper plate of the chain tensioner at
Plate upward position.
(e) Using a wrench, rotate the camshaft No. 2 clockwise to
push in the plunger of the chain tensioner.
(f) Remove the screwdriver from the service hole, then align
the hole of the stopper plate with the service hole and in-
sert a 2 to 3 mm (0.08 to 0.12 in.) diameter bar into the
A50158 holes to hold the stopper plate.

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14–10
ENGINE MECHANICAL – VALVE CLEARANCE

HINT:

Fix the stopper plate using the bar while rotating the cam-
shaft right and left slightly.

Hold the bar with tape so that the bar does not come off.

(g) Hold the camshaft with a wrench on the hexagonal lobe,

and remove the bolt.
SST 09023–38400

SST
A50157

(h) Using several steps, loosen and remove the 11 bearing

1 3 5 4 2 cap bolts uniformly in the sequence shown in the illustra-
tion, then remove the 5 bearing caps.
NOTICE:
Loosen each bolt uniformly keeping the camshaft level.

A35760

(i) Remove the fringe bolt with the No. 2 camshaft lifting up,
then detach the No. 2 camshaft and camshaft timing
sprocket.

A37148

(j) Using several steps, loosen and remove the 8 bearing

cap bolts uniformly in the sequence shown in the illustra-
tion, then remove the 4 bearing caps.
NOTICE:
Loosen each bolt uniformly keeping the camshaft level.

2 4 3 1
A35766

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ENGINE MECHANICAL – VALVE CLEARANCE

(k) Hold the timing chain by hand, and remove the camshaft
and camshaft timing gear assembly.

A35767

(l) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the chain cover.

A35227

(m) Remove the valve lifters.

(n) Using a micrometer, measure the thickness of the re-
moved lifter.
(o) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
A Thickness of new lifter
B Thickness of used lifter
C Measured valve clearance
A01082 Specified value (Cold):
Intake A = B + (C – 0.20 mm (0.008 in.))
Exhaust A = B + (C – 0.30 mm (0.012 in.))
(p) Select a new lifter with a thickness as close as possible
to the calculated values.
EXAMPLE (Intake):
Measured valve clearance = 0.40 mm (0.0158 in.)
0.40 mm (0.0158 in.) – 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.)
(Measured – Specification = Excess clearance)
Used lifter measurement = 5.25 mm (0.2067 in.)
0.20 mm (0.0079 in.) + 5.25 mm (0.2067 in.) = 5.45 mm (0.2146 in.)
(Excess clearance + Used lifter = Ideal new lifter)
Closest new lifter = 5.45 mm (0.2146 in.)
Select No. ”46” lifter (5.46 mm (0.2150 in.))

HINT:

Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).

Refer to the New Lifter Thickness table on the next 2
pages.

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 14–12
2004 SCION xB REPAIR MANUAL (RM1031U)
Valve Lifter Selection Chart (Intake)

ENGINE MECHANICAL
–
New lifter thickness mm (in.)

VALVE CLEARANCE
Lifter Lifter Lifter
Thickness Thickness No. Thickness
No. No.
Author:

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)

Date:

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)

Intake valve clearance (Cold):
0.15 to 0.25 mm (0.006 to 0.010 in.) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and 5.260 (0.2071) 50 5.740 (0.2260)
26 5.500 (0.2165) 74
the measured clearance is 0.400 mm (0.0158 in.).
A01234
957

Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter. 28 5.280 (0.2079) 52 5.520 (0.2173)
 2004 SCION xB REPAIR MANUAL (RM1031U)
Valve Lifter Selection Chart (Exhaust)

ENGINE MECHANICAL
–
VALVE CLEARANCE
New lifter thickness mm (in.)
Lifter Lifter Lifter
Thickness Thickness No. Thickness
No. No.
Author:

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)

Date:

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)

Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.010 to 0.014 in.) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)

14–13
958

the measured clearance is 0.440 mm (0.0173 in.).

A01235

28 5.280 (0.2079) 52 5.520 (0.2173)

Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.
14–14
ENGINE MECHANICAL – VALVE CLEARANCE

(q) Reinstall the valve lifters.

(r) Apply a light coat of engine oil on the camshaft journals.

Painted Link (s) Install the timing chain to the camshaft timing gear with
the painted link and timing marks aligned as shown in the
illustration.

Timing Mark A50141

(t) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque: 13 N⋅m (129 kgf⋅cm, 9.4 ft⋅lbf)
NOTICE:
Tighten each bolt uniformly keeping the camshaft level.

A37107

Painted Link (u) Hold the timing chain, and align the timing mark on the
camshaft timing sprocket with the painted link of the tim-
ing chain.

Timing Mark A50065

(v) Align the alignment pin hole located on the camshaft tim-
ing sprocket with the alignment pin of the camshaft, and
install the sprocket to the camshaft.
(w) Temporarily install the timing sprocket bolt.

A37148

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ENGINE MECHANICAL – VALVE CLEARANCE

5 3 1 2 4 (x) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque: 13 N⋅m (129 kgf⋅cm, 9.4 ft⋅lbf)
NOTICE:
Tighten each bolt uniformly keeping the camshaft level.
(y) Install the bearing cap No. 1.
Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf)

A35763

(z) Hold the camshaft with a wrench on the hexagon lobe,

and install the bolt.
Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf)
(aa) Remove the bar from the timing chain tensioner.

SST
A50157

(ab) Turn the crankshaft damper, and align its timing notch
with the timing mark ”0” of the chain cover.
(ac) Check that all the pairs of the timing marks are aligned.

Timing Marks

A38016

(ad) Apply seal packing to 2 or 3 threads of the screw plug end.

Seal packing:
Part No. 08833 – 00070 or equivalent
(ae) Using an 8 mm hexagon wrench, install the screw plug.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)

A37101

9. INSTALL CYLINDER HEAD COVER SUB–ASSY

(a) Apply seal packing to the 2 locations shown in the illustra-
tion.
Seal packing: Part No. 08826 – 00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.
Seal Packing
A50172
Do not start the engine within 2 hours of installation.

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14–16
ENGINE MECHANICAL – VALVE CLEARANCE

11
(b) Install the cylinder head cover with the 9 bolts, 2 seal
washers and 2 nuts.
(c) Using several steps, tighten the bolts and nuts uniformly
in the sequence shown in the illustration.
10 Torque: 10 N⋅m (102 kgf⋅cm, 7.4 ft⋅lbf)
10. INSTALL IGNITION COIL NO.1
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)

A35756

11. INSTALL CYLINDER HEAD COVER NO.2

(a) First tighten nut A, then tighten bolt B.
Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf)

A50920

12. INSTALL ENGINE UNDER COVER RH

Torque:
5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for Bolt
5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for Nut
13. CHECK FOR ENGINE OIL LEAKS

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Author: Date: 961