Engine Mechanical: Adjustments Toyota Celica T230 рестайлинг

ADJUSTMENT

Note. Inspect and adjust the valve clearance when the engine is cold.

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1. Remove cylinder head cover . See «REMOVAL»(ref-163200-S28314870632005020100000) .
2. Set No. 1 cylinder to TDC/compression . Turn the crankshaft pulley, and align its groove with the timing mark"0" of the timing chain cover. Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
3. Inspect valve clearance : Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement of adjusting shim. Valve clearance (Cold): 1ZZ-FE: Intake 0.15 -- 0.25 mm (0.006 -- 0.010 in.) Exhaust 0.25 -- 0.35 mm (0.010 -- 0.014 in.) 2ZZ-GE: Intake 0.08 -- 0.18 mm (0.0031 -- 0.0071 in.) Exhaust 0.22 -- 0.32 mm (0.0087 -- 0.0126 in.) Turn the crankshaft 1 revolution (360°) and align the mark as above. See procedure in step 2 . Check only the valves indicated as shown. Measure the valve clearance. See procedure in steps a ( 1 and 2 .
4. 1ZZ-FE: Adjust valve clearance : Set the No. 1 cylinder to the TDC/compression (See procedure in step 2 ). Place matchmarks on the timing chain and camshaft timing sprockets. Remove the 2 bolts and chain tensioner. NOTE: When holding the timing chain, disconnect the timing chain from the camshaft timing sprocket. Remove the camshaft and timing sprocket assemblies. See «REMOVAL»(ref-163200-S13032368722005020100000) . 19 camshaft bearing cap bolts 9 camshaft bearing caps (No. 1 & No. 3) Exhaust camshaft and timing sprocket assembly Intake camshaft and timing sprocket assembly NOTE: Be careful not to drop anything inside the timing chain cover. Do not allow the chain to come into contact with water or dust. Tie the timing chain with a string as shown in the illustration. Remove the valve lifters. Determine the size of the replaced valve lifter according to these Formula or Charts: Using a micrometer, measure the thickness of the removed lifter. Calculate the thickness of a new lifter so the valve clearance comes within the specified value. T..... Thickness of used lifter A..... Measured valve clearance N..... Thickness of new lifter Intake: N = T + (A -- 0.20 mm (0.008 in.)) Exhaust: N = T + (A -- 0.30 mm (0.012 in.)) NOTE: Lifter 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.). Select a new lifter with a thickness as close as possible to the calculated values.
5. 2ZZ-GE: Adjust valve clearance : NOTE: Remove the spark plug and take off the compression. Set the SST. Turn the crankshaft so that the related rocker arm, where the valve clearance is adjusted, is fully pushed down. NOTE: SST cannot be inserted unless the set screw is loosened. Make sure that the camshaft is in the same condition as step (1). Insert SST into the plug tube. SST 09248-77010 (09248-07010) NOTE: 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. Operate the lever so that SST's seat surface comes to contact with the valve retainer and lock them with the set screw. Lock the set screw on the plug tube side of SST. NOTE: 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. Rotate the crankshaft so that the camshaft is positioned as shown in the illustration. Remove the adjusting shim. NOTE: Do not remove SST in the condition that the adjusting shim is removed. Setting SST from the right above makes the removal easy. If there is not enough room, reset SST. Lift the rocker arm to make a room and remove the adjusting shim using SST. SST 09248-77010 (09248-07020) NOTE: Shim are available in 41 size in increments of 0.020 mm (0.0008 in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.). Determine the size of the replaced shim according to these Formula or Charts: Using dial indicator, 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 used shim A..... Measured valve clearance N..... Thickness of new shim Intake: N = T+ (A -- 0.13 mm (0.0051 in.)) x 1.5 Exhaust: N = T+ (A -- 0.27 mm (0.0106 in.)) x 1.5 Select a new shim with a thickness as close as possible to the calculated values.
6. 1ZZ-FE: Reinstall camshaft : Reinstall the valve lifters. See «REASSEMBLY»(ref-163200-S28092204682005020100000) . Align the crankshaft pulley groove with the timing mark"0" of the timing chain cover. Hold the timing chain, and place the intake camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshaft timing sprocket. Reinstall the camshaft and timing sprocket assemblies. See «INSTALLATION»(ref-163200-S02167951622005020100000) . Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration. Check that the matchmarks are on the timing chain and camshaft timing sprockets. Install the chain tensioner. See «INSTALLATION»(ref-163200-S33740329352005020100000) . Recheck the valve clearance (See procedure in step 3 ). Check the valve timing. See «INSTALLATION»(ref-163200-S33740329352005020100000) .
7. 2ZZ-GE: Reinstall adjusting shim : NOTE: 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. Lift the rocker arm to make a room and use SST, install the adjusting shim. NOTE: 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. Turn the crankshaft so that the related rocker arm, where the valve clearance is adjusted, is fully pushed down. After loosening the 2 set screws of SST, remove SST itself. SST 09248-77010 (09248-07010)
8. Reinstall cylinder head cover See «INSTALLATION»(ref-163200-S33740329352005020100000) .
9. If valve or rocker arm is replaced, replace shim as follows : Install a standard shim of 2.400 mm (0.0945 in.) thickness at low temperature and install the rocker arm. While pressing the rocker arm, measure the clearance"A" of valve"b" in the condition that a clearance of the other value is 0mm (0 in.). To adjust the valve hight, replace a shim of valve"b" with a shim that has thickness of t 1 . t 1 = A + 2.400 After adjusting the valve hight, adjust the clearance as described from step 3.

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1. Warm up engine : Allow the engine to warm up to normal operating temperature.
2. Connect toyota hand-held tester or obdii scan tool : Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand-held tester or OBDII scan tool operator's for further details.
3. Connect timing light to engine .
4. Using a timing light, check the ignition timing : Ignition timing: 1ZZ-FE: 10 -- 18° BTDC @ idle 2ZZ-GE: 8 -- 12° BTDC @ idle (Transmission in neutral position) HINT: After engine rpm is kept at 1,000 -- 1,300 rpm for 5 seconds, check that it returns to idle speed.
5. Disconnect timing light from engine .
6. Disconnect toyota hand-held tester or OBDII scan tool .

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1. Install conditions : Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All vacuum lines properly connected SFI system wiring connectors fully plugged All operating accessories switched OFF Ignition timing check correctly Transmission in neutral position Air conditioning switched OFF
2. Connect toyota hand-held tester or OBDII scan tool : Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand-held tester or OBDII scan tool operator's manual for further details.
3. Inspect idle speed : Race the engine at 2,500 rpm for approximatley 90 seconds. Check the idle speed. Idle speed (w/ Cooling fan OFF): 1ZZ-FE M/T 700 +/- 50 rpm A/T 750 +/- 50 rpm 2ZZ-GE M/T 800 +/- 50 rpm A/T 750 +/- 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system.
4. Disconnect toyota hand-held tester or OBDII scan tool .

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1. Remove upper front fender apron seal and upper radiator support seal .
2. Drain engine coolant .
3. Remove RH front wheel .
4. Remove RH engine under cover .
5. Remove drive belt and generator . See «REMOVAL»(ref-173160-S23088450822005031000000) .
6. Disconnect PS pump from engine : Disconnect the PS oil pressure switch connector. NOTE: Put aside the pump and suspend it to the cowl with a string. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.
7. Remove RH engine mounting insulator : NOTE: Place a wooden block between the jack and engine. Set the jack to the engine. 1ZZ-FE: Remove the 4 bolts, 2 nuts and RH engine mounting insulator. 2ZZ-GE: Remove the 5 bolts, 2 nuts and RH engine mounting insulator.
8. 1ZZ-FE: Remove cylinder head cover : Remove the 4 bolts and No. 2 cylinder head cover. Remove the 4 ignition coils. See «REMOVAL & INSTALLATION»(ref-133226-S41582560472002021900000) . Disconnect the 2 PCV hoses from the cylinder head. Remove the 9 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket.
9. 2ZZ-GE: Remove cylinder head cover : Remove the 4 bolts and No. 2 cylinder head cover. Remove the ignition coils. See «REMOVAL & INSTALLATION»(ref-133226-S41582560472002021900000) . Disconnect the 2 PCV hoses from the cylinder head cover. Remove the 2 nuts, bolt and disconnect the No. 3 ventilation hose from the No. 1 ventilation pipe. Remove the No. 1 ventilation pipe and gasket. Remove the 9 bolts, wire harness protector, cylinder head cover and gasket. Remove the O-ring from the cylinder head cover.
10. 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 sprockets are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
11. Remove crankshaft pulley : Using SST and 2 nuts (width: 10 mm (0.25 in.)), remove the pulley bolt. SST 09213-70010, 09330-00021 NOTE: If necessary, remove the pulley with SST. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) Remove the crankshaft pulley.
12. Disconnect crankshaft position sensor from timing chain cover : Remove the 2 bolts and crankshaft position sensor.
13. Remove the bolt, nut and drive belt tensioner.
14. Remove RH engine mounting bracket : 1ZZ-FE: Remove the 3 bolts and mounting bracket. 2ZZ-GE: Remove the 4 bolts and mounting bracket.
15. Remove the 2 nuts and chain tensioner.
16. Remove «WATER PUMP»(ref-171346-S05943887562005020100000) .
17. 1ZZ-FE: Remove timing chain cover : Remove the 11 bolts and nut. Using a torx wrench socket (E8), remove the stud bolt. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver.
18. 2ZZ-GE: Remove timing chain cover : Remove the 12 bolts. Using a torx wrench socket (E8), remove the stud bolt. Remove the timing chain cover and 2 gaskets.
19. Remove crank angle sensor plate .
20. Remove the bolt and chain tensioner slipper.
21. Remove timing chain and crankshaft timing sprocket : If the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers.
22. Remove 2 bolts and chain vibration damper .
23. Remove valve timing control assembly and camshaft timing sprocke . Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt, valve timing controller assembly and timing sprocket.

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1. Inspect timing chain and timing sprockets : NOTE: Make the same measurements pulling at 3 or more places selected at random. Using a vernier calipers, measure the length of 16 links with the chain dully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) If the elongation is greater than maximum, replace the chain. Wrap the chain around the timing sprocket. NOTE: Vernier calipers must contact the chain rollers for measuring. Using a vernier calipers, measure the timing sprocket diameter with the chain. Minimum sprocket diameter (w/Chain): Camshaft 97.3 mm (3.831 in.) Crankshaft 51.6 mm (2.031 in.) If the diameter is less than minimum, replace the chain and sprockets.
2. Inspect chain tensioner slipper and vibration damper : Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the slipper and/or damper.
3. Inspect chain tensioner : Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
4. Inspect oil jet . See «INSPECTION»(ref-171349-S00856459522005020200000) .