Valve: Adjustments

Special Tools:

CAUTION: It is necessary to change the adjusting shims to correct the valve clearance. This requires removal of the camshafts.

NOTE: The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine.

NOTE: Steps which only apply to certain model variants and therefore do not apply to all vehicles are clearly marked.

1. Disconnect the battery ground cable.





2. Remove the air cleaner resonator and air cleaner outlet pipe.
1 Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2 Disconnect the Intake Air Temperature (IAT) electrical sensor.
3 Remove the one bolt and two nuts.
4 Release the retaining clips.





3. Disconnect the speed control cable.
1 Disconnect the cable from the throttle valve.
2 Move the cable up and down and pull it out of the retaining bushing.
3 Press the retaining bushing out of the bracket.





4. Disconnect the throttle cable.
1 Remove the plastic retaining clip.
2 Unhook the cable.

5. NOTE: Do not remove the upper part of the engine front cover.





Remove the bolts.





6. Remove the appearance cover.
1 Disconnect the solenoid valve electrical connector.
2 Remove the eight bolts.

7. NOTE: Loosening sequence: From the outside inwards, working diagonally.





Remove the valve cover.
1 Disconnect the HT wires from the spark plugs.
2 Disconnect the crankcase ventilation hose.
3 Remove the 10 bolts.

8. Loosen the right-hand front wheel nuts.
9. Raise and support the vehicle.
10. Remove the right-hand front wheel.

11. CAUTION: Only turn the engine by the crankshaft and in the normal direction of rotation.





Set the crankshaft to TDC on cylinder No. 1

12. CAUTION: Do not rotate the engine.

NOTE: The Variable Camshaft Timing (VCT) unit has no function when the engine is switched off.





Using an open-ended wrench, gently turn the exhaust camshaft by the hexagon in the normal direction of rotation until the VCT unit reaches its stop.

13. CAUTION: Make a note of the measured valve clearances by cylinder and valve.





Measure the valve clearances with a feeler gauge.
- Permissible valve clearance: intake 0.11-0.18 mm at 20°C±5°C
- Permissible valve clearance: exhaust 0.27-0.34 mm at 20°C±5°C

14. CAUTION: Only rotate the engine by the crankshaft.

Measure the valve clearances (continued).
- Rotate the engine by the crankshaft in the direction of engine rotation through another 180 degrees. The sequence of measurements is given by the firing order: 1-3-4-2.
- Measure the valve clearances on all other cylinders.

15. NOTE: Only carry out the following two steps if the valves need adjusting.

If the required valve clearances are not obtained, remove the camshafts.

NOTE: A mid-range valve clearance is preferred (intake 0.15 mm, exhaust 0.30 mm).

16. NOTE: The number on the shim corresponds to the shim thickness. Example: 222 = 2.22 mm





Measure the required shim thickness.
- Remove the adjusting shim from the tappets and read off the size from the back (if it is not legible measure it with a micrometer).
- Measure and insert the shim of the required thickness.
- Intake valves: required shim thickness = fitted shim thickness + measured valve clearance-0.15 mm.
- Exhaust valves: required shim thickness = fitted shim thickness + measured valve clearance-0.30 mm.

17. NOTE: Use a thumb to press the locating pins of the gasket into the holes.





Install a new gasket into the oil feed flange.





18. Prepare the exhaust camshaft for installation.
1 Insert the oil feed ring into the oil feed flange.
2 Slide both components together onto the exhaust camshaft.





19. Thinly coat the camshaft bearing cap No. 5 with sealant.





20. Insert the camshafts.
- Lubricate the valve tappets with engine assembly lubricant and insert them.
- Lubricate the camshaft bearings with engine assembly lubricant.
- Insert the intake camshaft.
1 Hold the oil feed flange upwards during installation of the exhaust camshaft.
2 Position the oil feed ring hole right to the top.

NOTE: Keep the oil feed flange away from the cylinder head when turning the flange to avoid damaging the gasket.

3 Turn the oil feed flange till the locating lug is in the installation position on the cylinder head.
21. Insert new exhaust camshaft oil seal.

22. NOTE: The numbering is on the outside of the camshaft bearing caps.





Insert the camshaft bearing caps.

NOTE: Make sure the upright seat of the exhaust camshaft oil seal during tightening process of camshaft bearing caps.

23. NOTE: Working evenly in several stages, screw in each bolt two turns at a time.

NOTE: Tighten in sequence.





Tighten the camshaft bearing bolts.





24. Using the special tool, install the intake camshaft oil seal.





25. Check the valve clearance.

NOTE: The measurement of the valve clearance is the same anywhere along the base circle of the cam.

- Using an open-ended wrench, turn the intake camshaft by the hexagon until the cams on cylinder No. 1 are vertical above the valve tappets. Hold the camshaft in this position, and measure and make note of the valve clearance.
- Repeat the measurement on the exhaust camshaft and all the other cylinders.
- Remove the camshafts, as necessary and repeat steps to until the required valve clearance is achieved.

26. Continue with the assembly.

27. NOTE: Tightening sequence: From the inside outwards, working diagonally.





Install the valve cover with a new gasket and a new solenoid valve oil seal.
1 Install in the 10 bolts.
2 Connect the crankcase ventilation hose.
3 Connect the HT wires to the spark plugs.





28. Install the appearance cover.
1 Install the eight bolts.
2 Connect the solenoid valve electrical connector and press in the rubber seal.

29. NOTE: Check the seating of the upper part of the engine front cover gasket and correct as necessary.





Install the bolts.





30. Connect the throttle cable.
1 Hook the cable in place.
2 Install the cable in the bracket and slide on the plastic clip.





31. Connect the speed control cable.
1 Press the retaining bushing into the bracket.

NOTE: An audible click indicates that it has snapped into place.

2 Slide the cable into the retaining bushing.
3 Connect the cable to the throttle valve.





32. Install the air cleaner resonator and air cleaner outlet tube.
1 Position the resonator and outlet. tube and secure.
2 Install the one bolt and two nuts.
3 Connect the IAT sensor electrical connector.
4 Connect the MAF electrical connector.

33. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 Km (10 miles) or more to relearn the strategy.

Connect the battery ground cable.
34. Check the fluid levels and correct as necessary.
35. Check the routing of the vacuum hoses and wiring and secure them with cable ties.