Valve Clearance: Adjustments
VALVE CLEARANCEADJUSTMENT
1. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 4 nuts and cylinder head cover No. 2.
2. REMOVE IGNITION COIL NO.1
a. Remove the 4 bolts and pull out the 4 ignition coils.
3. DISCONNECT VENTILATION HOSE
a. Disconnect the ventilation hose from the cylinder head cover.
4. DISCONNECT VENTILATION HOSE NO.2
a. Disconnect the ventilation hose No. 2 from the cylinder head cover.
5. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the 9 bolts and 2 nuts, and then remove the cylinder head cover.
6. REMOVE ENGINE UNDER COVER RH
7. INSPECT VALVE CLEARANCE
HINT: Inspect and adjust the valve clearance when the engine is cold.
a. Set the No. 1 cylinder to the TDC/compression.
1. Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
2. Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.
HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
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 inch)
Exhaust 0.25 to 0.35 mm (0.010 to 0.014 inch)
2. Record any 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 until its timing notch and the timing mark "0" of the chain cover are aligned.
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 inch)
Exhaust 0.25 to 0.35 mm (0.010 to 0.014 inch)
2. Record any out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
8. ADJUST VALVE CLEARANCE
NOTICE: 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 the pistons from coming into contact with the valves.
a. Set the No. 1 cylinder to the TDC/compression.
1. Turn the crankshaft damper until its timing notch and timing mark "0" of the chain cover are aligned.
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.
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.
c. Using an 8 mm hexagon wrench, remove the screw plug.
d. Insert a screwdriver into the service hole of the chain tensioner to the hole 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.
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 inch) diameter bar into the holes to hold the stopper plate.
HINT:
^ Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
^ 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
h. Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration, then remove the 5 bearing caps.
NOTICE: Loosen each bolt uniformly keeping the camshaft level.
i. Remove the fringe bolt with the No. 2 camshaft lifting up, then detach the No. 2 camshaft and camshaft timing sprocket.
j. Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, then remove the 4 bearing caps.
NOTICE: Loosen each bolt uniformly keeping the camshaft level.
k. Hold the timing chain by hand, and remove the camshaft and camshaft timing gear assembly.
l. Tie the timing chain with a string as shown in the illustration.
NOTICE: Be careful not to drop anything inside the chain cover.
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.
A Thickness of new lifter
B Thickness of used lifter
C Measured valve clearance
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.008 inch))
Exhaust A = B + (C - 0.30 mm (0.012 inch))
p. Select a new lifter with a thickness as close as possible to the old lifter.
HINT:
^ Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).
^ Refer to the New Lifter Thickness table on the next 2 pages.
Valve Lifter Selection Chart (Intake)
Valve Lifter Selection Chart (Exhaust)
q. Reinstall the valve lifters.
r. Apply a light coat of engine oil to the camshaft journals.
s. Install the timing chain onto the camshaft timing gear with the painted link and timing marks aligned as shown in the illustration.
t. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft. lbs.)
NOTICE: Tighten each bolt uniformly keeping the camshaft level.
u. Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the painted link of the timing chain.
v. Align the alignment pin hole located on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket into the camshaft.
w. Temporarily install the timing sprocket bolt.
x. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft. lbs.)
NOTICE: Tighten each bolt uniformly keeping the camshaft level.
y. Install the bearing cap No. 1.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
z. Hold the camshaft with a wrench on the hexagon lobe, and install the bolt.
SST 09023-38400
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
aa. Remove the bar from the timing chain tensioner.
ab. Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
ac. Check that all the pairs of the timing marks are aligned.
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 Nm (153 kgf-cm, 11 ft. lbs.)
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
NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes of applying seal packing.
^ Do not start the engine for at least 2 hours of installation.
b. Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.
c. Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)
10. INSTALL IGNITION COIL NO.1
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
11. INSTALL CYLINDER HEAD COVER NO.2
a. First tighten A nuts, then tighten bolts B.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
12. INSTALL ENGINE UNDER COVER RH
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for bolt
5.0 Nm (51 kgf-cm, 44 inch lbs.) for nut
13. CHECK FOR ENGINE OIL LEAKS