Toyota Highlander Hybrid 6 2005-06

Valve Lash (Clearance) Adjustment

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2.4L Engine




NOTE
Adjust the valve clearance when the engine is cold.

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

    Negative battery cable. If equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Right front wheel, splash shield and apron seal
     
    engine undercover
     
    Coil pack
     
    Air intake hoses
     
    Cylinder head cover
     

  4.  
  5. Place the No.1 piston at TDC compression. Check only those valves shown. Record the clearance. If out of clearance, the measurement will be used to calculate the adjusting shims.

    Click image to see an enlarged view

    Fig. Check the clearance on these valves with the engine at No.1 TDC compression-2.4L Highlander

  6.  
  7. Place the No.4 piston at TDC compression. Check only those valves shown. Record the clearance. If out of clearance, the measurement will be used to calculate the adjusting shims.

    Click image to see an enlarged view

    Fig. Check the clearance on these valves with the engine at No.4 TDC compression-2.4L Highlander

  8.  

Clearance range is:



Intake: 0.19-0.29mm (0.008-0.011 in.)
 
Exhaust: 0.30-0.40mm (0.012-0.016 in.)
 

To adjust the valves:

  1. Turn the crankshaft 1 complete revolution (360 degrees) clockwise and set the No.1 piston at TDC compression. Place matchmarks on the chain and camshaft sprocket.
  2.  
  3. Remove the tensioner.
  4.  
  5. Loosen the camshaft sprocket bolt.
  6.  
  7. Remove the exhaust camshaft bearing caps, raise the camshaft and remove the sprocket. Tie the chain out of the way.
  8.  
  9. Remove the camshaft.
  10.  
  11. Remove the lifters and keep them in order.

    Click image to see an enlarged view

    Fig. Measure the lifters at the point shown-2.4L Highlander



    Click image to see an enlarged view

    Fig. Intake valve lifter selection chart-2.4L Highlander



    Click image to see an enlarged view

    Fig. Exhaust valve lifter selection chart-2.4L Highlander

  12.  
  13. Measure the thickness of any lifter on which the clearance was out of range. Calculate the thickness of the necessary replacement lifter. Lifters are available in 0.020mm increments from 5.060mm to 5.740mm.
  14.  
  15. For Camshaft and Timing Chain installation, see the respective procedures in this section.
  16.  

Hybrid




NOTE
Adjust the valve clearance when the engine is cold.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the coolant from the engine radiator and hybrid transaxle.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Right-hand front wheel
     
    Engine splash shields
     
    Right-hand front fender apron seal
     
    Wiper and blade assembly
     
    Top cowl ventilator louver assembly
     
    Wiper motor and link assembly
     
    Battery and battery tray
     
    Air intake assembly
     
    Emission control valve hoses
     
    Air intake surge tank
     
    Radiator intake hose
     
    Brake master cylinder reservoir and bracket
     
    Air cleaner bracket
     
    Engine moving control rod
     
    Right-hand engine No.2 mounting stay
     
    Ignition coil
     
    Valve covers
     

  10.  
  11. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover.
  12.  
  13. Check that the valve lifters on the No. 1 cylinder (intake and exhaust) are loose. If not, turn the crankshaft 1 complete revolution (360 degrees).
    NOTE
    All measurements should be written down. These recorded measurements will need to be used in conjunction with a mathematical formula to determine the thickness of the replacement shims.

  14.  
  15. Measure the clearance between the valve lifters and the camshaft. Record the measurements on valves No. 1 and 6 intake; No. 2 and 3 exhaust.

    Click image to see an enlarged view

    Fig. Adjust these valves during the 1st step

    1. The intake valve clearance cold is 0.006-0.010 in. (0.15-0.25mm).
    2.  
    3. The exhaust valve clearance cold is 0.010-0.014 in. (0.25-0.35mm).
    4.  

  16.  
  17. Turn the crankshaft 2 / 3 of a revolution (240 degrees). Record the measurements on valves No. 2 and 3 intake; No. 4 and 5 exhaust.

    Click image to see an enlarged view

    Fig. Adjust these valves during the 2nd step

  18.  
  19. Turn the crankshaft another 2 / 3 of a revolution (240 degrees). Record the measurements on valves No. 4 and 5 intake; No. 1 and 6 exhaust.

    Click image to see an enlarged view

    Fig. Adjust these valves during the 3rd step

  20.  
  21. Remove the adjusting shim by turning the crankshaft to position the cam lobe of the camshaft in the up position on the valve to be adjusted. Using a small thin flat bladed tool, turn the valve lifter so that the notches are perpendicular to the camshaft. Press down the valve lifter with tool 09248-55010 part A. Place too 09248-55010 part B between the camshaft and the valve lifter; remove part A.
  22.  
  23. Remove the adjusting shim with a magnet and a small screwdriver.
  24.  
  25. Determine the replacement adjusting shim size by either using the charts or the following formulas:

    Intake: N = T + (A - 0.008 in./0.020mm)
     
    Exhaust: N = T + (A - 0.012 in./0.30mm)
     
    T = Thickness of removed shim
     
    A = Measured valve clearance
     
    N = Thickness of new shim
     

  26.  
  27. Select a new shim with a thickness as close as possible to the calculated value. Install the new replacement shim.
    NOTE
    Shims are available in 17 sizes in increments of 0.0020 in. (0.050mm), from 0.0984 in. (2.500mm) to 0.1299 in. (3.300mm).

  28.  
  29. Recheck the valve clearance.
  30.  
  31. Install or connect the following:

    Valve covers
     
    Ignition coil
     
    Radiator intake hose
     
    Air intake surge tank
     
    Emission control valve hoses
     
    Air intake assembly
     
    Battery and battery tray
     
    Wiper motor and link assembly
     
    Top cowl ventilator louver assembly
     
    Wiper and blade assembly
     
    Right-hand front fender apron seal
     
    Engine splash shields
     
    Right-hand front wheel
     
    Engine covers
     
    Negative battery cable
     

  32.  
  33. Refill the cooling system to the correct level.
  34.  
  35. Refill the engine oil to the correct level.
  36.  
  37. Start the engine and check for leaks.
  38.  
  39. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  40.  

 
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