Valve Clearance: Adjustments

VALVE CLEARANCE ADJUSTMENT [L3]

1. Disconnect the negative battery cable.
2. Remove the tire (RH).
3. Remove the splash shield (RH).
4. Remove the plug hole plate.
5. Remove the spark plugs.
6. Remove the oil control valve (OCV) connector.
7. Remove the ventilation hose.
8. Remove the cylinder head cover.
9. Remove the drive belt.
10. Remove the front drive shaft (RH) from the joint shaft.





11. Remove the engine front cover lower blind plug.





12. Remove the engine front cover upper blind plug.
13. Remove the cylinder block lower blind plug.





14. Install the SST as shown in the figure.
15. Rotate the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is contacting the SST).
16. Loosen the timing chain.





(1) Unlock the chain tensioner ratchet using a suitable screwdriver or equivalent tool.
(2) Rotate the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen a timing chain.
(3) Placing the suitable bolt (M6 X 1.0 length 25-35 mm (0.99-1.37 in)) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.





17. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.





18. Remove the exhaust camshaft sprocket.





19. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure.

Note:
^ The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly. When removed, keep the caps with the cylinder head from where they were removed. Do not mix the caps.

20. Remove the camshaft.
21. Remove the tappet.
22. Select proper adjustment shim.

New adjustment shim
= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm (0.0098 in), EX: 0.30 mm (0.0118 in))

Standard [Engine cold]
IN: 0.22-0.28 mm (0.0087-0.0110 in)
EX: 0.27-0.33 mm (0.0107-0.0129 in)





23. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.
24. Install the camshaft with No.1 cylinder aligned with the TDC position.





25. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.





26. Tighten the camshaft cap bolt in the following two steps.
(1) Tighten to 5.0-9.0 N-m (51.0-91.7 kgf-cm, 44.3-79.6 in-lbf).
(2) Tighten to 14.0-17.0 N-m (1.5-1.7 kgf-m, 10.4-12.5 ft-lbf).





27. Install a new washer.





28. Install the exhaust camshaft sprocket.

Note:
^ Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.





29. Install the SST to the camshaft as shown in the figure.
30. Remove the (M6 X 1.0 length 25mm-35mm (0.99-1.37 in)) bolt from the engine front cover to apply tension to the timing chain.
31. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is contacting to the SST).





32. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
33. Tighten the exhaust camshaft sprocket lock bolt.

Tightening torque 69-75 N-m (7.1-7.6 kgf-m, 50.9-55.3 ft-lbf)

34. Remove the SST from the camshaft.
35. Remove the SST from the block lower blind plug.
36. Rotate the crankshaft two times clockwise until the crankshaft is in the TDC position, reinstall the SSTs to the camshaft and cylinder block, and inspect the valve timing.
^ If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 16.
37. Apply silicone sealant to the engine front cover upper blind plug.





38. Install the engine front cover upper blind plug.

Tightening torque 8.0-11.5 N-m (81.6-117.2 kgf-cm, 70.9-101.7 in-lbf)





39. Install the cylinder block lower blind plug.

Tightening torque 18-22 N-m (1.9-2.2 kgf-m, 13.3-16.2 ft-lbf)





40. Install the new engine front cover lower blind plug.

Tightening torque 10.0-14.0 N-m (102.0-142.7 kgf-cm, 73.8-103.2 in-lbf)

41. Connect the front drive shaft (RH).
42. Install the drive belt.
43. Install the cylinder head cover.
44. Install the ventilation hose.
45. Install the oil control valve (OCV) connector.
46. Install the spark plugs.
47. Install the plug hole plate.
48. Install the splash shield (RH).
49. Install the tire (RH).