valve clearance (2zz–ge)

14–179
ENGINE MECHANICAL
–
VALVE CLEARANCE (2ZZ–GE)
VALVE CLEARANCE (2ZZ–GE)
140R6–01
ADJUSTMENT
1.
2.
(a)
REMOVE ENGINE UNDER COVER RH
REMOVE CYLINDER HEAD COVER NO.2
Remove the 3 bolts, the nut and the cylinder head cover No. 2.
3.
(a)
REMOVE IGNITION COIL ASSY
Remove the 3 bolts and the nut, and disconnect the 4 connectors, and remove the 4 ignition coils.
4.
(a)
(b)
REMOVE WIRE HARNESS CLAMP
Disconnect the engine wire harness.
Remove the bolt and wiring harness clamp bracket.
5.
(a)
(b)
DISCONNECT SUCTION HOSE SUB–ASSY
Remove the 2 nuts installing the suction hose sub–assy.
Disconnect the suction hose sub–assy.
6.
(a)
REMOVE CYLINDER HEAD COVER SUB–ASSY
Disconnect the fuel hose clamp and 2 PCV hoses from
the cylinder head cover.
A65805
A65803
A65804
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1444
14–180
ENGINE MECHANICAL
(b)
(c)
–
VALVE CLEARANCE (2ZZ–GE)
Remove the 2 nuts, bolt and disconnect the No. 3 ventilation hose from the No. 1 ventilation pipe.
Disconnect the ventilation No. 1 tube and gasket.
A10385
(d)
(e)
Remove the 8 bolts, wire harness protector, cylinder head
cover and gasket.
Remove the O–ring from the cylinder head cover.
A65845
7.
(a)
REMOVE FAN AND GENERATOR V BELT
Turn the drive belt tensioner slowly clockwise and loosen
it. Then, remove the drive belt and put back the drive belt
tensioner little by little and fix it quietly.
8.
REMOVE ENGINE MOUNTING
SUB–ASSY RH
Set the jack to the engine.
B00145
INSULATOR
(a)
HINT:
Place a wooden block between the jack and engine.
A66151
(b)
Remove the 5 bolts, 2 nuts and engine mounting insulator
sub–assy RH.
A59841
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1445
14–181
ENGINE MECHANICAL
9.
(a)
Mark
(b)
–
VALVE CLEARANCE (2ZZ–GE)
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Turn the crankshaft pulley, and align its groove with timing
mark ”0” of the timing chain cover.
Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360) and align the
marks as above.
Mark
Timing Chain
Cover Surface
Groove
A59787
10. REMOVE V–RIBBED BELT TENSIONER ASSY
HINT:
Handle a jack up and down to remove the bolt.
11.
(a)
A35925
A35924
2003 COROLLA MATRIX
INSPECT VALVE CLEARANCE
Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
(2) Record the out–of specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold)
Intake
0.08 – 0.18 mm (0.0031 – 0.0071 in.)
Exhaust
0.22 – 0.32 mm (0.0087 – 0.0126 in.)
(b)
Turn the crankshaft 1 revolution (360 ) and set No. 4 cylinder to TDC/compression.
(c)
Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
(2) Record the out–of specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold)
Intake
0.08 – 0.18 mm (0.0031 – 0.0071 in.)
Exhaust
0.22 – 0.32 mm (0.0087 – 0.0126 in.)
218W (RM940U)
Author:
Date:
1446
14–182
ENGINE MECHANICAL
–
VALVE CLEARANCE (2ZZ–GE)
12.
(a)
ADJUST VALVE CLEARANCE
Set the SST.
(1) Turn the crankshaft so that the related rocker
arm,where the valve clearance is adjusted, is fully
pushed down.
NOTICE:
Remove the spark plug and take off the compression.
A13535
SST
(2) Insert SST into the plug tube.
SST 09248–77010 (09248–07010)
NOTICE:
SST cannot be inserted unless the set screw is loosened.
Make sure that the camshaft is in the same condition
as step (1).
A13536
(3)
SST
Set
Screw
A13537
Operate the lever so that SST’s seat surface comes
to contact with the valve retainer and lock them with
the set screw.
NOTICE:
Clearance between the valve retainer and SST’s seat
surface is not allowed.
Care should be taken not to make clearance when inserting SST, since a presence of clearance may unlock the keeper.
(4) lock the set screw on the plug tube side of SST.
(5) Rotate the crankshaft so that the camshaft is positioned as shown in the illustration.
NOTICE:
Pay attention to the direction of the rotation to prevent
the nose of the camshaft from interfering with the
SST’s shaft.
Do not rotate the crankshaft excessively.
A63543
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1447
14–183
ENGINE MECHANICAL
–
VALVE CLEARANCE (2ZZ–GE)
(b)
SST
A13539
Remove the adjusting shim.
(1) Lift the rocker arm to make a room and remove the
adjusting shim using SST.
SST 09248–77010 (09248–07010)
NOTICE:
Do not remove SST in the condition that adjusting shim is
removed.
HINT:
Setting SST from the right above makes the removal
easy.
If there is not enough room, reset SST.
(2)
Determine the size of the replaced shim according
to there Formula or Charts:
Using a dial indicator, measure the thickness
of the removed shim.
Calculate the thickness of a new shim so that
the valve clearance comes within the specified value.
A
A35527
Thickness of new shim
B
Thickness of used shim
C
Measured valve clearance
Intake: A = B + (C – 0.13 mm (0.005 in.)) × 1.5
Exhaust: A = B + (C – 0.27 mm (0.011 in.)) × 1.5
HINT:
Shim are available in 41 sizes in increments of 0.020 mm
(0.0008 in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102
in.).
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1448
14–184
2003 COROLLA MATRIX
2ZZ–GE: Valve Shim Selection Chart (Intake)
ENGINE MECHANICAL
218W (RM940U)
–
Date:
A10466
1449
Intake valve clearance (Cold):
0.08 – 0.18 mm (0.0031 – 0.0071 in.)
EXAMPLE: The 2.200 mm (0.0826 in.) shim is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 2.600 mm (0.1024 in.) shim with a new No. 60 shim.
Shim
No.
00
02
04
06
08
10
12
14
16
18
20
22
24
26
Thickness
2.000 (0.0787)
2.020 (0.0795)
2.040 (0.0803)
2.060 (0.0811)
2.080 (0.0819)
2.100 (0.0827)
2.120 (0.0835)
2.140 (0.0843)
2.160 (0.0850)
2.180 (0.0858)
2.200 (0.0866)
2.220 (0.0874)
2.240 (0.0882)
2.260 (0.0890)
Shim
No.
28
30
32
34
36
38
40
42
44
46
48
50
52
54
Thickness
2.280 (0.0898)
2.300 (0.0906)
2.320 (0.0913)
2.340 (0.0921)
2.360 (0.0929)
2.380 (0.0937)
2.400 (0.0945)
2.420 (0.0953)
2.440 (0.0961)
2.460 (0.0969)
2.480 (0.0976)
2.500 (0.0984)
2.520 (0.0992)
2.540 (0.1000)
mm (in.)
Shim
No.
56
58
60
62
64
66
68
70
72
74
76
78
80
Thickness
2.560 (0.1008)
2.580 (0.1016)
2.600 (0.1024)
2.620 (0.1031)
2.640 (0.1039)
2.660 (0.1047)
2.680 (0.1055)
2.700 (0.1063)
2.720 (0.1071)
2.740 (0.1079)
2.760 (0.1087)
2.780 (0.1094)
2.800 (0.1102)
VALVE CLEARANCE (2ZZ–GE)
Author:
New Shim thickness
2003 COROLLA MATRIX
2ZZ–GE: Valve Shim Selection Chart (Exhaust)
ENGINE MECHANICAL
218W (RM940U)
–
Date:
Thickness
2.000 (0.0787)
2.020 (0.0795)
2.040 (0.0803)
2.060 (0.0811)
2.080 (0.0819)
2.100 (0.0827)
2.120 (0.0835)
2.140 (0.0843)
2.160 (0.0850)
2.180 (0.0858)
2.200 (0.0866)
2.220 (0.0874)
2.240 (0.0882)
2.260 (0.0890)
Shim
No.
28
30
32
34
36
38
40
42
44
46
48
50
52
54
Thickness
2.280 (0.0898)
2.300 (0.0906)
2.320 (0.0913)
2.340 (0.0921)
2.360 (0.0929)
2.380 (0.0937)
2.400 (0.0945)
2.420 (0.0953)
2.440 (0.0961)
2.460 (0.0969)
2.480 (0.0976)
2.500 (0.0984)
2.520 (0.0992)
2.540 (0.1000)
Shim
No.
56
58
60
62
64
66
68
70
72
74
76
78
80
Thickness
2.560 (0.1008)
2.580 (0.1016)
2.600 (0.1024)
2.620 (0.1031)
2.640 (0.1039)
2.660 (0.1047)
2.680 (0.1055)
2.700 (0.1063)
2.720 (0.1071)
2.740 (0.1079)
2.760 (0.1087)
2.780 (0.1094)
2.800 (0.1102)
14–185
A10467
1450
Exhaust valve clearance (Cold):
0.22 – 0.32 mm (0.0087 – 0.0126 in.)
EXAMPLE: The 2.200 mm (0.0862 in.) shim is installed, and
the measured clearance is 0.500 mm (0.0197 in.).
Replace the 2.540 mm (0.1000 in.) shim with a new No. 54 shim.
Shim
No.
00
02
04
06
08
10
12
14
16
18
20
22
24
26
mm (in.)
VALVE CLEARANCE (2ZZ–GE)
Author:
New Shim thickness
14–186
ENGINE MECHANICAL
(c)
–
VALVE CLEARANCE (2ZZ–GE)
Lift the rocker arm to make a room and use SST, install the
adjusting shim.
HINT:
SST
Setting SST from the right above makes the removal
easy.
To remove SST from the adjusting shim, it is advisable to
push down the rocker arm.
A13540
(d)
13.
Turn the crankshaft so that the related rocker arm, where
the valve clearance is adjusted, is fully pushed down.
NOTICE:
Pay attention to the direction of the rotation to prevent
the nose of the camshaft from interfering with the
SST’s shaft.
Do not rotate the crankshaft excessively.
(e) After loosening the 2 set screws of SST, remove SST itself.
A63544
SST 09248–77010(09248–07010)
INSTALL V–RIBBED BELT TENSIONER ASSY
Torque:
Nut 29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf)
Bolt 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf)
14.
(a)
A59841
INSTALL ENGINE MOUNTING INSULATOR
SUB–ASSY RH
Install the engine mounting insulator sub–assy RH with
the 5 bolts and the 2 nuts.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
INSTALL CYLINDER HEAD COVER SUB–ASSY
Remove any old packing (FIPG) material.
15.
(a)
HINT:
When FIPG on the head cover gasket side cannot be eliminated completely, replace the gasket.
(b)
(c)
Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826–00080 or equivalent
Install the cylinder head cover gasket to the cylinder head
cover.
HINT:
Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.
A35926
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1451
14–187
ENGINE MECHANICAL
–
VALVE CLEARANCE (2ZZ–GE)
(d)
Install the new spark plug tube gasket and a new O–ring
to the cylinder head cover.
(e)
Install the cylinder head cover and wire harness protector
with the 8 bolts. Uniformly tighten the bolts, in the several
passes, in the sequence shown.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
Connect the PCV hoses to the cylinder head cover.
A65838
(f)
A65845
(g)
(h)
Install a new gasket and No. 1 ventilation pipe with 2 nuts
and bolt.
Torque:
Nut 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
Bolt 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf)
Connect the No. 3 ventilation hose to the No. 1 ventilation
pipe.
A10385
16.
INSTALL SUCTION HOSE SUB–ASSY
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)
17.
INSTALL WIRE HARNESS CLAMP
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
A65804
A65803
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1452
14–188
ENGINE MECHANICAL
18.
–
VALVE CLEARANCE (2ZZ–GE)
INSTALL IGNITION COIL ASSY
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
A65805
19.
20.
INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf)
INSPECT OIL LEAK
2003 COROLLA MATRIX
218W (RM940U)
Author:
Date:
1453