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    Toyota Matrix 2003-06

    Valve Lash (Clearance) Adjustment

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    Click image to see an enlarged view

    Fig. Adjusting shim chart (intake)-1ZZ-FE engine

    Adjusting shim chart (intake)-1ZZ-FE engine

    Click image to see an enlarged view

    Fig. Adjusting shim chart (exhaust)-1ZZ-FE engine

    Adjusting shim chart (exhaust)-1ZZ-FE engine

    Click image to see an enlarged view

    Fig. Adjusting shim chart (intake)-2ZZ-GE engine

    Adjusting shim chart (intake)-2ZZ-GE engine

    Click image to see an enlarged view

    Fig. Adjusting shim chart (exhaust)-2ZZ-GE engine

    Adjusting shim chart (exhaust)-2ZZ-GE engine

    Click image to see an enlarged view

    Fig. Adjusting shim chart (intake)-1ZZ-FE engine

    Adjusting shim chart (intake)-1ZZ-FE engine

    Click image to see an enlarged view

    Fig. Adjusting shim chart (exhaust)-1ZZ-FE engine

    Adjusting shim chart (exhaust)-1ZZ-FE engine

    Click image to see an enlarged view

    Fig. Adjusting shim chart (intake)-2ZZ-FE ENGINE

    Adjusting shim chart (intake)-2ZZ-FE ENGINE

    Click image to see an enlarged view

    Fig. Adjusting shim chart (exhaust)-2ZZ-FE ENGINE

    Adjusting shim chart (exhaust)-2ZZ-FE ENGINE

    1ZZ-FE Engine




    NOTE
    Adjust the valve clearance when the engine is cold.

    1. Before servicing the vehicle, refer to the Precautions section.
      2.  
    2. Remove or disconnect the following:

      Negative battery cable.
       
      Cylinder head covers
       
      Engine wire
       
      Ignition coil
       
      Positive Crankcase Ventilation (PCV) hoses
       
      Cylinder head cover sub-assembly
       

      3.  
    3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
      1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
        2.  
      2. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.
        3.  

      4.  
    4. Check the valve clearance of the first set of the valves shown:
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0059-0.0098 in. (0.15-0.25mm). The clearance of the exhaust valves should be 0.0098-0.0138 in. (0.25-0.35mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  
      3. Turn the crankshaft 1 revolution (360°) to set the No. 4 cylinder to TDC.
        4.  



      Click image to see an enlarged view

      Fig. Check the clearance of the 1st set of valves-1ZZ-FE engine

      Check the clearance of the 1st set of valves-1ZZ-FE engine
      5.  
    5. Check the valve clearance of the second set of the valves shown:
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0059-0.0098 in. (0.15-0.25mm). The clearance of the exhaust valves should be 0.0098-0.0138 in. (0.25-0.35mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  



      Click image to see an enlarged view

      Fig. Check the clearance of the 2nd set of valves-1ZZ-FE engine

      Check the clearance of the 2nd set of valves-1ZZ-FE engine
      6.  
    6. Remove or disconnect the following:

      Drive belt
       
      Right side engine mount
       
      Drive belt tensioner
       

      7.  


      Click image to see an enlarged view

      Fig. Proper timing mark alignment for TDC-1ZZ-FE and 2ZZ-GE engines

      Proper timing mark alignment for TDC-1ZZ-FE and 2ZZ-GE engines


    WARNING
    DO NOT turn the crankshaft while the tensioner is removed!

    1. Set the No. 1 cylinder to TDC of the compression stroke.

      Camshafts
       
      Valve lifters.
       

      2.  
    2. Use a micrometer to measure the thickness of the used lifter. Calculate the thickness of a new lifter. so the valve clearance comes within the specified value:
      1. A: Thickness of new lifter.
        2.  
      2. B: Thickness of used lifter.
        3.  
      3. C: Measured valve clearance.
        4.  
      4. Intake valve clearance: A = B + (C - 0.0079 in. (0.20mm).
        5.  
      5. Exhaust valve clearance: A = B + (C - 0.0118 in. (0.30mm).
        6.  
      6. Select a new lifter with a thickness as close as possible to the calculated values. Lifters come in 35 sizes in increments of 0.0008 in. (0.020mm) from 0.1992-0.2260 in (5.060-5.740mm).
        7.  

      3.  
    3. Install or connect the following:

      Camshafts
       
      Drive belt tensioner
       
      Right hand engine mount
       
      Cylinder head (valve) cover sub-assembly
       
      Ignition coil
       
      Engine wire
       
      Cylinder head (valve) cover
       
      Negative battery cable
       

      4.  


    NOTE
    Adjust the valve clearance when the engine is cold.

    1. Before servicing the vehicle, refer to the precautions section.
      2.  
    2. Remove or disconnect the following:

      Negative battery cable.
       
      Cylinder head covers
       
      Engine wire
       
      Ignition coil
       
      Positive Crankcase Ventilation (PCV) hoses
       
      Cylinder head cover sub-assembly
       

      3.  
    3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
      1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
        2.  
      2. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.

        Click image to see an enlarged view

        Fig. Proper timing mark alignment for TDC-1ZZ-FE and 2ZZ-FE Engines

        Proper timing mark alignment for TDC-1ZZ-FE and 2ZZ-FE Engines
        3.  

      4.  
    4. Check the valve clearance of the first set of the valves shown:

      Click image to see an enlarged view

      Fig. Check the clearance of the 1st set of valves-1ZZ-FE engine

      Check the clearance of the 1st set of valves-1ZZ-FE engine
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0059-0.0098 in. (0.15-0.25mm). The clearance of the exhaust valves should be 0.0098-0.0138 in. (0.25-0.35mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  
      3. Turn the crankshaft 1 revolution (360°) to set the No. 4 cylinder to TDC.
        4.  

      5.  
    5. Check the valve clearance of the second set of the valves shown:

      Click image to see an enlarged view

      Fig. Check the clearance of the 2nd set of valves-1ZZ-FE engine

      Check the clearance of the 2nd set of valves-1ZZ-FE engine
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0059-0.0098 in. (0.15-0.25mm). The clearance of the exhaust valves should be 0.0098-0.0138 in. (0.25-0.35mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  

      6.  
    6. Remove or disconnect the following:
      WARNING
      DO NOT turn the crankshaft while the tensioner is removed!



      Drive belt
       
      Right side engine mount
       
      Drive belt tensioner
       

      7.  
    7. Set the No. 1 cylinder to TDC of the compression stroke.

      Camshafts
       
      Valve lifters.
       

      8.  
    8. Use a micrometer to measure the thickness of the used lifter. Calculate the thickness of a new lifter. so the valve clearance comes within the specified value:
      1. A: Thickness of new lifter.
        2.  
      2. B: Thickness of used lifter.
        3.  
      3. C: Measured valve clearance.
        4.  
      4. Intake valve clearance: A = B + (C - 0.0079 in. (0.20mm).
        5.  
      5. Exhaust valve clearance: A = B + (C - 0.0118 in. (0.30mm).
        6.  
      6. Select a new lifter with a thickness as close as possible to the calculated values. Lifters come in 35 sizes in increments of 0.0008 in. (0.020mm) from 0.1992-0.2260 in (5.060-5.740mm).
        7.  

      9.  
    9. Install or connect the following:

      Camshafts
       
      Drive belt tensioner
       
      Right hand engine mount
       
      Cylinder head (valve) cover sub-assembly
       
      Ignition coil
       
      Engine wire
       
      Cylinder head (valve) cover
       
      Negative battery cable
       

      10.  

    2zz-FE Engine




    NOTE
    Adjust the valve clearance when the engine is cold.

    1. Before servicing the vehicle, refer to the precautions section.
      2.  
    2. Remove or disconnect the following:

      Negative battery cable.
       
      Right side engine under cover
       
      Cylinder head cover
       
      Ignition coil assembly
       
      Wire harness clamp
       
      Suction hose sub-assembly
       
      Cylinder head cover sub-assembly
       
      Drive belt
       
      Right side engine mount
       

      3.  
    3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
      1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
        2.  
      2. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.
        3.  

      4.  
    4. Check the valve clearance of the first set of the valves shown:

      Click image to see an enlarged view

      Fig. Check the clearance of the 1st set of valves-2ZZ-FE ENGINE

      Check the clearance of the 1st set of valves-2ZZ-FE ENGINE
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0031-0.0071 in. (0.08-0.18mm). The clearance of the exhaust valves should be 0.0087-0.0126 in. (0.22-0.32mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  
      3. Turn the crankshaft 1 revolution (360°) to set the No. 4 cylinder to TDC.
        4.  

      5.  
    5. Check the valve clearance of the second set of the valves shown:

      Click image to see an enlarged view

      Fig. Check the clearance of the 2nd set of valves-2ZZ-FE ENGINE

      Check the clearance of the 2nd set of valves-2ZZ-FE ENGINE
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0031-0.0071 in. (0.08-0.18mm). The clearance of the exhaust valves should be 0.0087-0.0126 in. (0.22-0.32mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  

      6.  
    6. To adjust the intake valve clearance:
      1. Set the SST. Turn the crankshaft so the related rocker arm, where the valve clearance is adjusted, is fully pushed down.
        NOTE
        Remove the spark plug and take off the compression.

        2.  
      2. Insert SST 09248-77010 into the plug tube. The tool cannot be inserted unless the set screw is loosened.

        Click image to see an enlarged view

        Fig. Insert the special tool into the plug tube-2ZZ-GE

        Insert the special tool into the plug tube-2ZZ-GE
        3.  
      3. Operate the lever so that the SST-s seat surface comes to contact with the valve retainer and lock them with the set screw. Clearance between the valve retainer and SST-s set surface is not allowed. Be careful not to make clearance when inserting the SST, since clearance may unlock the keeper.

        Click image to see an enlarged view

        Fig. Operate the lever so that the SST-s seat surface comes to contact with the valve retainer and lock them with the set screw

        Operate the lever so that the SST-s seat surface comes to contact with the valve retainer and lock them with the set screw
        4.  
      4. Lock the set screw on the tube side of the SST.
        5.  
      5. Rotate the crankshaft so that the camshaft is position as shown. During rotation, pay attention to the direction, to prevent the nose of the camshaft from interfering with the SST-s shaft. Do not rotate the crankshaft excessively.
        6.  
      6. Lift the rocker arm to make room and remove the adjusting shim using SST 09248-77010.

        Click image to see an enlarged view

        Fig. Setting the tool from the right side, makes shim removal easier-2ZZ-GE

        Setting the tool from the right side, makes shim removal easier-2ZZ-GE
        7.  

      7.  
    7. Determine the size of the replaced shim according to the chart or the following formula:
      1. Use a dial indicator to measure the thickness of the removed shim.
        2.  
      2. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
        3.  
      3. A: Thickness of new shim.
        4.  
      4. B: Thickness of used shim.
        5.  
      5. C: Measured valve clearance.
        6.  
      6. Intake: A = B + (C - 0.005 in. [0.13mm])
        7.  
      7. Exhaust: A = B + (C - 0.011 in. [0.27mm])
        8.  
      8. Select a new shim with a thickness as close as possible to the calculated values. Shims come in 41 sizes in increments of 0.0008 in. (0.020mm) from 0.0787-0.1102 in (2.0-2.8mm).
        9.  

      8.  
    8. Lift the rocker arm to make room, then install the adjusting shim using the SST. To remove the tool from the shim, push down on the rocker arm.
      9.  
    9. Turn the crankshaft so the related rocker arm, where the valve clearance is adjusted, is fully pushed down.
      10.  
    10. Loosen the 2 set-screws, then remove the SST.
      11.  
    11. Install all components in the reverse of the removal procedure.
      12.  

    2ZZ-GE Engine




    NOTE
    Adjust the valve clearance when the engine is cold.

    1. Before servicing the vehicle, refer to the Precautions section.
      2.  
    2. Remove or disconnect the following:

      Negative battery cable.
       
      Right side engine under cover
       
      Cylinder head cover
       
      Ignition coil assembly
       
      Wire harness clamp
       
      Suction hose sub-assembly
       
      Cylinder head cover sub-assembly
       
      Drive belt
       
      Right side engine mount
       

      3.  
    3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
      1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
        2.  
      2. Make sure the point marks of the camshaft timing sprockets and VVT timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.
        3.  

      4.  
    4. Check the valve clearance of the first set of the valves shown:
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0031-0.0071 in. (0.08-0.18mm). The clearance of the exhaust valves should be 0.0087-0.0126 in. (0.22-0.32mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  
      3. Turn the crankshaft 1 revolution (360°) to set the No. 4 cylinder to TDC.
        4.  



      Click image to see an enlarged view

      Fig. Check the clearance of the 1st set of valves-2ZZ-GE engine

      Check the clearance of the 1st set of valves-2ZZ-GE engine
      5.  
    5. Check the valve clearance of the second set of the valves shown:
      1. Use a feeler gauge to measure the clearance between the valve lifter and camshaft. The clearance of the intake valves should be 0.0031-0.0071 in. (0.08-0.18mm). The clearance of the exhaust valves should be 0.0087-0.0126 in. (0.22-0.32mm).
        2.  
      2. Note the out-of-specification valve clearance measurements. You will need them later to determine the required replacement valve lifter.
        3.  



      Click image to see an enlarged view

      Fig. Check the clearance of the 2nd set of valves-2ZZ-GE engine

      Check the clearance of the 2nd set of valves-2ZZ-GE engine
      6.  
    6. To adjust the intake valve clearance:
      1. Set the SST. Turn the crankshaft so the related rocker arm, where the valve clearance is adjusted, is fully pushed down.
        2.  

      7.  


    NOTE
    Remove the spark plug and take off the compression.

    1. Insert SST 09248-77010 into the plug tube. The tool cannot be inserted unless the set screw is loosened.
      2.  


      Click image to see an enlarged view

      Fig. Insert the special tool into the plug tube-2ZZ-GE

      Insert the special tool into the plug tube-2ZZ-GE
    2. Operate the lever so that the SST-s seat surface comes to contact with the valve retainer and lock them with the set screw. Clearance between the valve retainer and SST-s set surface is not allowed. Be careful not to make clearance when inserting the SST, since clearance may unlock the keeper.
      3.  


      Click image to see an enlarged view

      Fig. Operate the lever so that the SST-s seat surface comes to contact with the valve retainer and lock them with the set screw

      Operate the lever so that the SST-s seat surface comes to contact with the valve retainer and lock them with the set screw
    3. Lock the set screw on the tube side of the SST.
      4.  
    4. Rotate the crankshaft so that the camshaft is position as shown. During rotation, pay attention to the direction, to prevent the nose of the camshaft from interfering with the SST-s shaft. Do not rotate the crankshaft excessively.
      5.  
    5. Lift the rocker arm to make room and remove the adjusting shim using SST 09248-77010.
      6.  



    Click image to see an enlarged view

    Fig. Setting the tool from the right side, makes shim removal easier-2ZZ-GE

    Setting the tool from the right side, makes shim removal easier-2ZZ-GE
    1. Determine the size of the replaced shim according to the chart or the following formula:
      1. Use a dial indicator to measure the thickness of the removed shim.
        2.  
      2. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
        3.  
      3. A: Thickness of new shim.
        4.  
      4. B: Thickness of used shim.
        5.  
      5. C: Measured valve clearance.
        6.  
      6. Intake: A = B + (C - 0.005 in. [0.13mm])
        7.  
      7. Exhaust: A = B + (C - 0.011 in. [0.27mm])
        8.  
      8. Select a new shim with a thickness as close as possible to the calculated values. Shims come in 41 sizes in increments of 0.0008 in. (0.020mm) from 0.0787-0.1102 in (2.0-2.8mm).
        9.  

      2.  
    2. Lift the rocker arm to make room, then install the adjusting shim using the SST. To remove the tool from the shim, push down on the rocker arm.
      3.  
    3. Turn the crankshaft so the related rocker arm, where the valve clearance is adjusted, is fully pushed down.
      4.  
    4. Loosen the 2 set-screws, then remove the SST.
      5.  
    5. Install all components in the reverse of the removal procedure.
      6.  

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