2004 Scion xA
2004 ENGINE Valve Clearance - xA
2004 ENGINE
Valve Clearance - xA
VALVE CLEARANCE
ADJUSTMENT
1. REMOVE CYLINDER HEAD COVER NO. 2
a. Remove the 4 nuts and the cylinder head cover No. 2.
Fig. 1: Removing Nuts And Cylinder Head Cover No. 2
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. REMOVE IGNITION COIL NO. 1
a. Remove the 4 bolts and pull out the 4 ignition coils.
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2004 ENGINE Valve Clearance - xA
Fig. 2: Removing Bolts And Pulling Out Ignition Coils
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. DISCONNECT VENTILATION HOSE
a. Disconnect the ventilation hose from the cylinder head cover.
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Fig. 3: Disconnecting Ventilation Hose From Cylinder Head Cover
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
4. DISCONNECT VENTILATION HOSE NO. 2
a. Disconnect the ventilation hose No. 2 from the cylinder head cover.
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2004 ENGINE Valve Clearance - xA
Fig. 4: Disconnecting Ventilation Hose No. 2 From Cylinder Head Cover
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the 9 bolts, the 2 nuts and cylinder head cover.
6. REMOVE ENGINE UNDER COVER RH
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2004 Scion xA
2004 ENGINE Valve Clearance - xA
Fig. 5: Removing Bolts And Nuts Of Cylinder Head Cover
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
7. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
a. Set the No. 1 cylinder to TDC/compression.
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 timing sprocket and camshaft timing gear
facing upward as shown in the illustration.
HINT:
If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
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2004 ENGINE Valve Clearance - xA
Fig. 6: Locating Timing Marks
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between 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 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.
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Fig. 7: Identifying Intake (IN) And Exhaust (EX) Valves - No. 1 Cylinder
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between 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 the required replacement adjusting shim.
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2004 Scion xA
2004 ENGINE Valve Clearance - xA
Fig. 8: Identifying Intake (IN) And Exhaust (EX) Valves - No. 4 Cylinder
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
8. ADJUST VALVE CLEARANCE
NOTE: 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.
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Fig. 9: Rotating Crankshaft Damper Counterclockwise 40° From TDC And Aligning Timing Notch
With Matchmark Of Timing Chain
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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 timing 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 the marks as above.
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Fig. 10: Identifying Timing Marks
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Put paint marks on the timing chain in place where the timing marks of the camshaft timing
sprocket and the camshaft timing gear are located.
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Fig. 11: Putting Paint Marks On Timing Chain
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Using an 8 mm hexagon wrench, remove the screw plug.
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2004 ENGINE Valve Clearance - xA
Fig. 12: Removing Screw Plug Using An Hexagon Wrench
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the
chain tensioner at upward position.
e. Using a wrench, rotate the camshaft No. 2 clockwise to push in the plunger of the chain tensioner.
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Fig. 13: Pushing In Plunger Of Chain Tensioner
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
f. Remove the screwdriver from the service hole, then align the hole of the stopper plate with the
service hole and insert a 2 to 3 mm (0.08 to 0.12 in.) diameter bar into the holes to hold the stopper
plate.
HINT:
lFix the stopper plate using the bar while rotating the camshaft right and left slightly.
l 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
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Fig. 14: Removing Bolt Of Camshaft
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
h. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown
in the illustration, then remove the 5 bearing caps.
NOTE: Loosen each bolt uniformly keeping the camshaft level.
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2004 ENGINE Valve Clearance - xA
Fig. 15: Identifying Sequence Of Removing Bearing Cap Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
i. Remove the fringe bolt with the No. 2 camshaft lifted up, then detach the No. 2 camshaft and the
camshaft timing sprocket.
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Fig. 16: Removing Fringe Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
j. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in
the illustration, then remove the 4 bearing caps.
NOTE: Loosen each bolt uniformly keeping the camshaft level.
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2004 ENGINE Valve Clearance - xA
Fig. 17: Identifying Removing Sequence Of Bearing Cap Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
k. Hold the timing chain by hand, and remove the camshaft and the camshaft timing gear assembly.
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2004 ENGINE Valve Clearance - xA
Fig. 18: Removing The Camshaft
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
l. Tie the timing chain with a string as shown in the illustration.
NOTE: Be careful not to drop anything inside the timing chain cover.
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Fig. 19: Tying The Timing Chain
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
m. Remove the valve lifters.
n. Using a micrometer, measure the thickness of the removed lifter.
o. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
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Fig. 20: Measuring The Thickness Of The Removed Lifter
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 21: Calculating The Thickness Of A New Lifter
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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 the thickness as close to the calculated values as possible.
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Fig. 22: Lifter Calculation (Example)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
HINT:
l 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.).
l Refer to the New Lifter Thickness table on the next page.
Fig. 23: Valve Lifter Selection Chart (Intake)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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Fig. 24: Valve Lifter Selection Chart (Exhaust)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
q. Reinstall the valve lifters.
r. Apply a light coat of engine oil on the camshaft journals.
s. Install the timing chain to the camshaft timing gear with the paint mark and the timing mark
aligned as shown in the illustration.
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Fig. 25: Aligning Paint Mark And Timing Mark
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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)
NOTE: Tighten each bolt uniformly keeping the camshaft level.
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Fig. 26: Tightening Sequence Of Bearing Cap Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
u. Hold the timing chain, and align the match mark on the camshaft timing sprocket with the paint
mark of the timing chain.
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Fig. 27: Aligning Match Mark On Camshaft Timing Sprocket With Paint Mark Of Timing
Chain
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
v. Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the
camshaft, and install the sprocket to the camshaft.
w. Temporarily install the timing sprocket bolt.
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Fig. 28: Aligning Alignment Pin Hole On Camshaft Timing Sprocket With Alignment Pin Of
Camshaft
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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)
NOTE: 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)
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Fig. 29: Numbering Bearing Cap Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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)
SST 09023-38400
aa. Remove the bar from the timing chain tensioner.
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Fig. 30: Installing Camshaft Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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.
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Fig. 31: Aligning Timing Notch With Timing Mark
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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)
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Fig. 32: Installing Screw Plug
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Apply seal packing to the 2 locations shown in the illustration.
Seal packing: Part No. 08826 - 00080 or equivalent
NOTE: l Remove any oil from the contact surface.
l Install the cylinder head cover within 3 minutes after applying
seal packing.
l Do not start the engine within 2 hours of installation.
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Fig. 33: Applying Seal Packing
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Install the cylinder head cover with the 9 bolts, the 2 seal washers and the 2 nuts.
c. Using several steps, tighten the bolts and the nuts uniformly in the sequence shown in the
illustration.
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)
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Fig. 34: Identifying Tightening Sequence Of Cylinder Head Cover Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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)
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Fig. 35: Tightening Cylinder Head Cover Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
12. CHECK FOR ENGINE OIL LEAKS
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