Toyota RAV4 2000-05

Valve Lash (Clearance) Adjustment 1

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2.4L Engine



Perform this procedure on a cold engine only!

  1. Remove the right side engine under-cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the cylinder head cover.
  6.  
  7. Turn the crankshaft pulley and align its groove with the -0- mark on the timing cover. This sets the engine to No. 1 TDC compression.
  8.  
  9. Check that the timing marks on the camshaft sprocket and VVT sprocket are aligned with the timing marks on the camshaft No.1 and 2 bearing caps.
  10.  


NOTE
Valve clearance (cold) should be 0.008-0.011 inch for intake; 0.012-0.016 inch for exhaust.

  1. Check the clearance on the Nos. 1 and 2 intake valves and the Nos. 1 and 3 exhaust valves, as shown.
  2.  
  3. Turn the crankshaft 1 full revolution clockwise (360 degrees).
  4.  
  5. Check the clearance on Nos. 3 and 4 intake, and Nos. 2 and 4 exhaust.
  6.  


    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley and align its groove with the -0- mark on the timing cover-2.4L engine



    Click image to see an enlarged view

    Fig. Check that the timing marks on the camshaft sprocket and VVT sprocket are aligned with the timing marks on the camshaft No.1 and 2 bearing caps-2.4L engine



    Click image to see an enlarged view

    Fig. Check the clearance on the Nos. 1 and 2 intake valves and the Nos. 1 and 3 exhaust valves-2.4L engine



    Click image to see an enlarged view

    Fig. Check the clearance on Nos. 3 and 4 intake, and Nos. 2 and 4 exhaust-2.4L engine


If Adjustment Is Needed



Click image to see an enlarged view

Fig. Remove the exhaust camshaft bearing caps, evenly, in several passes, in the sequence shown-2.4L engine



Click image to see an enlarged view

Fig. Remove the intake camshaft bearing caps, evenly, in several passes, in the sequence shown-2.4L engine



Click image to see an enlarged view

Fig. Tie the timing chain out of the way-2.4L engine



Click image to see an enlarged view

Fig. Using a micrometer, measure the lifter thickness-2.4L engine

  1. Reset the crankshaft to No. 1 TDC compression.
  2.  
  3. Place matchmarks on the timing chain and camshaft sprockets.
  4.  
  5. Remove the chain tensioner and gaskets.
  6.  
  7. Loosen the exhaust camshaft sprocket bolt.
  8.  
  9. Remove the exhaust camshaft bearing caps, evenly, in several passes, in the sequence shown.
  10.  
  11. Lift the camshaft and remove the sprocket together with the timing chain.
  12.  
  13. Remove the intake camshaft bearing caps, evenly, in several passes, in the sequence shown.
  14.  
  15. Remove the intake camshaft. Tie the timing chain out of the way as shown.
  16.  
  17. For any valve needing adjustment, remove the lifter. Determine replacement lifter size.
    1. Using a micrometer, measure the lifter thickness.
    2.  
    3. Calculate the thickness of a new liter to bring the valve clearance into the proper range.
    4.  
    5. Select a lifter with a thickness as close as possible to correct the specified value, from the accompanying charts. Lifters are available in 35 sizes in 0.0008 inch (0.020mm) increments from 5.060mm to 5.740mm.
    6.  

  18.  


    Click image to see an enlarged view

    Fig. An ID number inside the lifter shows the 2 decimal place size-2.4L engine



    Click image to see an enlarged view

    Fig. Intake valve lifter size selection chart-2.4L engine



    Click image to see an enlarged view

    Fig. Exhaust valve lifter size selection chart-2.4L engine



NOTE
An ID number inside the lifter shows the 2 decimal place size. So, a 38 mark would indicate a lifter that is 5.38mm thick.

  1. Coat the replacement lifter with clean engine oil and install it.
  2.  

  1. When all new lifters are installed, align the crankshaft timing mark with the -0- mark on the timing cover.
  2.  
  3. Hold the chain and install the intake camshaft, aligning all marks.
  4.  
  5. Coat the threads and heads of the bearing cap bolts with clean engine oil.
  6.  
  7. Torque the bolts evenly, in several passes, in the sequence shown, to 22 ft. lbs. (29.5 Nm) for Nos. 1 and 2; 80 inch lbs. (9 Nm) for all the others.
  8.  
  9. Install the exhaust camshaft, aligning all marks and install the bearing caps in the same manner as you did with the intake caps.
  10.  
  11. Recheck all timing marks.
  12.  
  13. Install the tensioner. Torque to 80 inch lbs. (9 Nm).
  14.  
  15. Recheck the valve timing by setting the crankshaft timing mark to align with the -0- mark on the timing cover. All timing marks should align
  16.  
  17. The remainder of installation is the reverse of removal.
  18.  


NOTE
Adjust the valve clearance when the engine is cold.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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.
  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.
  8.  

Clearance range is:



Intake: 0.19-0.29mm
 
Exhaust: 0.30-0.40mm
 

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 intake camshaft.
  10.  
  11. Remove the lifters and keep them in order.
  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.  

Perform this procedure on a cold engine only!

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    Wait at least 90 seconds after disconnecting the negative battery cable before starting any repair work to prevent air bag and seat belt pretensioner activation.

  4.  
  5. Remove the right side engine undercover.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the cylinder head cover.
  10.  
  11. Turn the crankshaft pulley and align its groove with the -0- mark on the timing cover. This sets the engine to No. 1 TDC compression.
  12.  
  13. Check that the timing marks on the camshaft sprocket and VVT sprocket are aligned with the timing marks on the camshaft No.1 and 2 bearing caps.
    NOTE
    Valve clearance (cold) should be 0.008-0.011 inch for intake; 0.012-0.016 inch for exhaust.

  14.  
  15. Check the clearance on the Nos. 1 and 2 intake valves and the Nos. 1 and 3 exhaust valves, as shown.
  16.  
  17. Turn the crankshaft 1 full revolution clockwise (360 degrees).
  18.  
  19. Check the clearance on Nos. 3 and 4 intake, and Nos. 2 and 4 exhaust.

    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley and align its groove with the -0- mark on the timing cover-2.4L engine



    Click image to see an enlarged view

    Fig. Check that the timing marks on the camshaft sprocket and VVT sprocket are aligned with the timing marks on the camshaft No.1 and 2 bearing caps-2.4L engine



    Click image to see an enlarged view

    Fig. Check the clearance on the Nos. 1 and 2 intake valves and the Nos. 1 and 3 exhaust valves-2.4L engine



    Click image to see an enlarged view

    Fig. Check the clearance on Nos. 3 and 4 intake, and Nos. 2 and 4 exhaust-2.4L engine

  20.  

If Adjustment Is Needed

Click image to see an enlarged view

Fig. Remove the exhaust camshaft bearing caps, evenly, in several passes, in the sequence shown-2.4L engine



Click image to see an enlarged view

Fig. Remove the intake camshaft bearing caps, evenly, in several passes, in the sequence shown-2.4L engine



Click image to see an enlarged view

Fig. Tie the timing chain out of the way-2.4L engine



Click image to see an enlarged view

Fig. Using a micrometer, measure the lifter thickness-2.4L engine

  1. Reset the crankshaft to No. 1 TDC compression.
  2.  
  3. Place matchmarks on the timing chain and camshaft sprockets.
  4.  
  5. Remove the chain tensioner and gaskets.
  6.  
  7. Loosen the exhaust camshaft sprocket bolt.
  8.  
  9. Remove the exhaust camshaft bearing caps, evenly, in several passes, in the sequence shown.
  10.  
  11. Lift the camshaft and remove the sprocket together with the timing chain.
  12.  
  13. Remove the intake camshaft bearing caps, evenly, in several passes, in the sequence shown.
  14.  
  15. Remove the intake camshaft. Tie the timing chain out of the way as shown.
  16.  
  17. For any valve needing adjustment, remove the lifter. Determine replacement lifter size.
    1. Using a micrometer, measure the lifter thickness.
    2.  
    3. Calculate the thickness of a new liter to bring the valve clearance into the proper range.
    4.  
    5. Select a lifter with a thickness as close as possible to correct the specified value, from the accompanying charts. Lifters are available in 35 sizes in 0.0008 inch (0.020mm) increments from 5.060mm to 5.740mm.
      NOTE
      An ID number inside the lifter shows the 2 decimal place size. So, a 38 mark would indicate a lifter that is 5.38mm thick.



      Click image to see an enlarged view

      Fig. An ID number inside the lifter shows the 2 decimal place size-2.4L engine



      Click image to see an enlarged view

      Fig. Intake valve lifter size selection chart-2.4L engine



      Click image to see an enlarged view

      Fig. Exhaust valve lifter size selection chart-2.4L engine

    6.  
    7. Coat the replacement lifter with clean engine oil and install it.
    8.  

  18.  
  19. When all new lifters are installed, align the crankshaft timing mark with the -0- mark on the timing cover.
  20.  
  21. Hold the chain and install the intake camshaft, aligning all marks.
  22.  
  23. Coat the threads and heads of the bearing cap bolts with clean engine oil.
  24.  
  25. Torque the bolts evenly, in several passes, in the sequence shown, to 22 ft. lbs. (29.5 Nm) for Nos. 1 and 2; 80 inch lbs. (9 Nm) for all the others.
  26.  
  27. Install the exhaust camshaft, aligning all marks and install the bearing caps in the same manner as you did with the intake caps.
  28.  
  29. Recheck all timing marks.
  30.  
  31. Install the tensioner. Torque to 80 inch lbs. (9 Nm).
  32.  
  33. Recheck the valve timing by setting the crankshaft timing mark to align with the -0- mark on the timing cover. All timing marks should align
  34.  
  35. The remainder of installation is the reverse of removal.
  36.  

2.7L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Intake air connector
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Spark plug wires
     
    Engine wiring harness clamps and harness
     
    Air conditioning compressor connector, if equipped with air conditioning
     
    Oil pressure sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Distributor connector
     
    Cylinder head cover
     

  8.  
  9. Set the No. 1 cylinder to Top Dead Center (TDC) of the compression stroke, as follows:
    1. Turn the crankshaft pulley clockwise and align its groove with the 0 mark on the timing chain cover.
    2.  
    3. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in a straight line on the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees) and align the marks.
    4.  

  10.  
  11. Inspect the valve clearance, as follows:
    1. Measure the clearance between the valve lifter and the camshaft. Measure the 1st and 2nd intake and the 1st and 3rd exhaust valves.
    2.  
    3. Turn the crankshaft pulley 1 revolution (360 degrees) and align the marks as above. Measure the 3rd and 4th intake and the 2nd and 4th exhaust valves.
    4.  

  12.  
  13. Valve clearance cold should be:

    Intake: 0.006-0.010 in. (0.15-0.25mm)
     
    Exhaust: 0.010-0.014 in. (0.25-0.35mm)
     

  14.  
  15. Adjust the valve clearance by using adjusting shims, as follows:
    1. Turn the camshaft so the cam lobe for the valve to be adjusted faces up.
    2.  
    3. Using SST 09248-55040, press down the valve lifter and place SST 09248-05420, between the camshaft and the valve lifter. Remove SST 09248-55040.
    4.  
    5. Remove the adjusting shim with a small flat prying tool and a magnetic finger.
    6.  
    7. Determine the replacement adjusting shim size according to the following formula or use the adjusting shim charts.
    8.  
    9. Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so the valve clearance comes within the specified value.

      T: Thickness of the removed shim
       
      A: Measured valve clearance
       
      N: Thickness of the new shim
       

    10.  
    11. Intake: N = T + (A-0.008 in. (0.20mm))
    12.  
    13. Exhaust: N = T + (A-0.012 in. (0.30mm))
    14.  
    15. Install a new adjusting shim. Place it on the valve lifter. Using the SST 09248-55040, press down the valve lifter and remove SST 09248-05420.
    16.  
    17. Recheck the valve clearance.
    18.  

  16.  
  17. Install or connect the following:

    Cylinder head cover
     
    Engine wiring harness and clamps
     
    Distributor connector
     
    ECT sensor connector
     
    Oil pressure sensor connector
     
    Air conditioning compressor connector, if disconnected
     
    Spark plug wires
     
    PCV hoses
     
    Intake air connector
     
    Negative battery cable
     

  18.  
  19. Refill with engine coolant.
  20.  
  21. Check the ignition timing.
  22.  

3.0L Engine




NOTE
Adjust the valve clearance when the engine is cold.

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

    Negative battery cable. If equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Accelerator/throttle cable from the throttle linkage
     
    Air cleaner cover, air flow meter and air duct assembly
     
    V-bank cover
     
    Emission control valve set
     
    Air intake chamber
     
    Engine harness from the injectors and the ignition coils
     
    Ignition coils and keep them in order for reassembly
     
    Spark plugs
     
    Cylinder head covers
     

  4.  
  5. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover.
  6.  
  7. Check that the valve lifters on the No. 1 intake are loose and the No. 1 exhaust are tight. 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.

  8.  
  9. 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-3.0L

    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.  

  10.  
  11. 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-3.0L

  12.  
  13. Turn the crankshaft another 2 / 3 of a revolution. 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-3.0L

  14.  
  15. 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.
  16.  
  17. Remove the adjusting shim with a magnet and a small screwdriver.
  18.  
  19. 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
     

  20.  
  21. 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).

  22.  
  23. Recheck the valve clearance.
  24.  
  25. Install or connect the following:

    Cylinder head covers
     
    Spark plugs and the ignition coils
     
    Engine wiring harness to the injectors and the coils
     
    Intake chamber
     
    Emission control valve set
     
    V-bank cover
     
    Air flow meter, air duct and air cleaner cover
     
    Negative battery cable
     

  26.  

 
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