Checking Valve Clearance
Checking The Valve Clearance
NOTE: Measurements should only be taken on a cold engine. A suitable temperature is approximately 20 Degree C.
Use feeler gauge 999 5752.
Press with a finger so that the feeler gauge lies parallel to the upper side of the valve lifter.
Move the feeler gauge sideways when taking the reading in order to obtain as accurate a measurement as possible.
The valve clearance measured on cold engines (approximately 20 degree C) should be:
Inlet valve 0.20 ± 0.03 mm.
Exhaust valve 0.40 ± 0.03 mm.
NOTE: The tolerances are less at setting.When checking the valve clearance through the plug hole the tolerances are larger.
Differences In Valve Clearance For Different Engines/Ambient Temperatures:
- 0.01 mm at 15 degree C
+ 0.01 mm at 25 degree C
+ 0.02 mm at 30 degree C
+ 0.03 mm at 35 degree C
+ 0.04 mm at 45 degree C
Correcting Measured Clearance
Lift out the upper section of the press tool.
Lift out the camshaft.
Adjust the play by replacing the valve lifters.
Other valve lifters are available as replacement part/replacement part kits.
Reinstall the camshaft and the upper section of the press tool. Tighten to 12 Nm.
Take a new measurement.
When The Correct Valve Clearance Is Reached
Remove
- the press tool 999 5765
- the camshaft
- the valve lifters.
NOTE: Carefully mark the valve lifters so that exact reinstallation can be carried out.
Example:
Intake side I1, I2, I3 - I10.
Exhaust side A1, A2, A3 - A10.
Repeat the procedure for measuring the valve clearance for all cylinders on both the intake and exhaust sides.
Installing Valve Lifters And Camshafts
Lubricate the valve guide wells.
Install all the valve lifters.
Lubricate the camshaft bearing seats and the upper sides of the valve lifters.
Position the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.
Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.
Applying Liquid Gasket
Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 1161 059 on the camshaft cover. Use roller 951 2767.
NOTE: The surface must be completely covered without any excess.
CAUTION: Ensure that no liquid gasket gets in to the oil ducts.
Installing The Camshaft Covers
Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
Install the camshaft cover.
Install press tool 999 5454 (2x).
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.
Install all the screws. Tighten the screws from the middle and outwards.
Remove the press tool 999 5454
Install
- the variable valve timing (VVT) solenoid. Use a new gasket
- the spark plugs. Tighten to 30 Nm
- the plugs for the test holes. Tighten to 20 Nm
- the crankcase ventilation hose to the top of the camshaft cover
- the ignition coils according to the earlier marking
- the ground terminals between the ignition coils.
Installing The Rear Camshaft Seal
To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.
NOTE: When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.
Use drift 999 5450.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.
NOTE: If there are wear grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.
Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing The Front Camshaft Seal
Lift up and position the brake fluid reservoir and the expansion tank on top of the engine.
Use drift 999 5718 on camshafts with variable valve timing units. Use drift 999 5719 on camshafts without variable valve timing.
Use new seals and lubricate the surface of the seal that the camshaft rotates against. Use the variable valve timing unit/timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.
Remove the drift.
Fixing The Crankshaft Position
Remove
- the mounting screws for the starter motor. Pull off the starter motor. Place the starter motor to one side
- the blind cover plug and the seal washer.
Turn the crankshaft slightly clockwise.
Install the crankshaft stop 999 5451 Ensure that it bottoms out against the cylinder block.
Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing The Timing Gear Pulley For The Camshafts
NOTE: The purpose of the section, Installing the VVT unit/timing gear pulley, described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.
Timing Gear Pulleys With Variable Valve Timing Units
Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit/timing gear onto the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counterclockwise as far as it will go.
Remove the center screw.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1 tooth before the marking on the upper timing cover.
CAUTION: Do not turn counter clockwise during this procedure.
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing (VVT) unit. Tighten to 120 Nm. Check that the variable valve timing unit does not rotate when tightening.
Install the center screw. Tighten to 35 Nm.
Timing Gear Pulleys Without Variable Valve Timing Units
Install the timing gear pulley. Install the screws.
Install two screws without tightening. Allow the third screw to protrude.
Adjust the timing gear pulleys so that the markings on the timing gear pulleys/upper timing cover correspond.
Installing The Timing Belt
Tighten the center screw on the belt tensioner. Tighten to 5 Nm.
Turn the variable valve timing unit clockwise to the stop.
Hold it secure in the limit position.
Install The Belt In The Following Order:
- crankshaft
- the idler pulley
- intake cam
- exhaust cam
- water pump
- belt tensioner.
NOTE: Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes. Also check that the markings correspond.
Tensioning The Timing Belt
This adjustment is always carried out on a cold engine. A suitable temperature is approximately 20 degree C.
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
NOTE: Check that the variable valve timing unit is in its limit position.
Tighten the three screws at the intake camshaft timing gear pulley. Tighten to 10 Nm.
Tighten the three screws at the exhaust camshaft timing gear pulley. Tighten to 20 Nm.
Turn the eccentric on the belt tensioner back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.
Hold the eccentric secure and tighten the center screw. Tighten to 20 Nm.
Check that the indicator is in the correct position.
Remove camshaft adjustment tool 999 5451 and crankshaft stop 999 5452.
Install the plug with a new blind cover plug. Tighten to 40 Nm.
Checking The Markings And Belt Tension
Press the timing belt to check that the indicator on the tensioner moves easily.
Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
Check that the indicator on the belt tensioner is within the marked position.
Remove the upper timing cover.
Finishing
Install
- front timing cover
- the auxiliaries belt
- the expansion tank
- the servo oil reservoir
- the bleed hose for the expansion tank.
Close the clamp and check that the hoses lie correctly.
Connect the connectors for the
- The ABS sensor by the right suspension turret
- the coolant level sensor in the expansion tank.
Install
- the starter motor
- the plastic nuts for the cover in the fender liner
- the right front wheel.
Install
- the trigger wheel.
NOTE: Ensure that the trigger wheel is correctly positioned against the camshaft.
- the camshaft position (CMP) sensor housing
- the cover at the rear of the exhaust camshaft
- the screws holding both the ground strips from the firewall to the cylinder head
- the upper engine stabilizer brace
- the cover over the ignition coils
- the upper timing cover
- the crankcase ventilation hose on the inlet hose
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the engine stabilizer brace between the suspension turrets. Secure the servo hose at the right mounting for the engine stabilizer brace in the bodywork
- the cable to the battery negative terminal.
Check
Check the level in the expansion tank and the brake fluid reservoir.
Test drive the engine until the thermostat opens and check for any leakage.