Valve Clearance: Adjustments

1. Disable airbag system as described under MAINTENANCE PROCEDURE/AIRBAG SYSTEM DISARMING.
2. Disconnect control cables from throttle body, then remove air cleaner hose.
3. Remove EGR pipe and throttle body bracket.
4. Remove throttle body with intake air connector.
5. Remove No. 3 timing belt cover and cylinder head rear cover.
6. Disconnect high-tension cords from spark plugs.
7. Remove No. 1, No. 2 and No. 3 cylinder head covers.

Fig. 24 Crankshaft Pulley Timing Mark At TDC:

Fig. 25 Camshaft Timing Marks At TDC:

8. Turn crankshaft pulley clockwise and align its groove with timing mark ``0'' of No. 1 timing belt cover, Fig. 24.
9. Ensure timing marks of camshaft pulleys are aligned with timing marks of No. 4 timing belt cover, Fig. 25. If they are not aligned, turn crankshaft clockwise one revolution.

Fig. 26 Camshaft Bearing Cap Bolt Torque Sequence:

Fig. 27 Checking Valve Clearance (first Step):

10. Uniformly torque camshaft bearing cap bolts to 14 ft. lbs. in sequence shown in Fig. 26.
11. Using a feeler gauge, measure clearance between valve lifter and camshaft on valves shown in Fig. 27. Valve clearance (cold) should be .006-.010 inch for intake valves and .010-.014 for exhaust valves.

Fig. 28 Checking Valve Clearance (second Step):

Fig. 29 Checking Valve Clearance (third Step):

12. Turn crankshaft clockwise 2/3 of a revolution and measure clearance of valves shown in Fig. 28.
13. Turn crankshaft clockwise another 2/3 of a revolution and measure clearance of valves shown in Fig. 29.
14. Record valve clearance measurements of those that are out of specification. They will be used later to determine required size of replacement adjusting shim.

Fig. 30 Aligning Valve Lifter Notches:

Fig. 31 Removing Valve Adjusting Shim:

15. If valve clearance is not within specifications, proceed as follows:
a. Turn crank until camshaft lobe is upward.
b. Turn valve lifter with a screwdriver so that its notches are perpendicular to camshaft, Fig. 30.
c. Press down valve lifter with shim removal tool 09248-55011 or equivalent. Place other shim removal tool, 09248-05021 or equivalent, between camshaft and lifter, Fig. 31. Remove shim with a screwdriver and a magnet.
c. Using a micrometer, measure shim thickness.
d. Calculate shim thickness using the following formulas: intake N=T+(A - .0007 inch), exhaust N=T+(A - .013 inch): T=thickness of used shim, A=measured valve clearance, N=thickness of new shim.
e. Place new shim on valve lifter. Press down lifter and remove shim removal tools.
f. Recheck valve clearance.
16. Install cylinder head covers and timing belt covers.
17. Install throttle body, EGR pipe, throttle body bracket and control cables.