Valve Clearance: Adjustments
VALVE CLEARANCEADJUSTMENT
1. REMOVE INTAKE AIR SURGE TANK
(a) Remove the intake air surge tank.
2. REMOVE IGNITION COIL ASSEMBLY
3. REMOVE SPARK PLUG
4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
6. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gears and sprockets are aligned with the timing marks of the bearing caps shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
7. INSPECT VALVE CLEARANCE
(a) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard valve clearance (Cold):
(2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
(b) Turn the crankshaft 2/3 of a revolution (240°).
(c) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard valve clearance (Cold):
(2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
(d) Turn the crankshaft 2/3 of a revolution (240°).
(e) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Standard valve clearance (Cold):
(2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
8. ADJUST VALVE CLEARANCE
(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover.
(2) Check that the timing marks of the camshaft timing gears and sprockets are aligned with the timing marks of the bearing caps shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
(3) Place paint marks on the chain links that correspond with the timing marks of the camshaft timing gears.
(b) Remove the No. 1 chain tensioner.
NOTICE:
^ Never rotate the crankshaft with the No. 1 chain tensioner removed.
^ When rotating the camshaft with the No. 1 chain removed, turn the crankshaft counterclockwise 40° from the TDC first.
(1) Remove the 4 bolts, timing chain cover plate and gasket.
(2) While rotating the stopper plate of the No. 1 chain tensioner upward, push in the plunger of the No. 1 chain tensioner as shown in the illustration.
(3) While rotating the stopper plate of the tensioner downward, insert a bar of [diameter]3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.
(4) Remove the 2 bolts and No. 1 chain tensioner.
(c) Remove the No. 2 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) While raising up the No. 2 chain tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.
(2) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing sprocket set bolt.
NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench.
(3) Separate the camshaft timing gear from the No. 2 camshaft.
(4) Rotate the camshaft counterclockwise using the wrench so that the cam lobes of the No. 1 cylinder face upward as shown in the illustration.
(5) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
(6) Remove the 4 bearing caps and No. 2 camshaft.
(d) Remove the No. 2 chain tensioner.
(1) Remove the No. 2 chain tensioner bolt, No. 2 chain tensioner and camshaft timing sprocket.
(e) Remove the No. 1 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt.
NOTICE:
^ Be careful not to damage the cylinder head and valve lifter with the wrench.
^ Do not disassemble the camshaft timing gear.
(2) Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear.
(3) Rotate the No. 1 camshaft counterclockwise using a wrench so that the cam lobes of the No. 1 cylinder face downward as shown in the illustration.
(4) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
(5) Remove the 4 bearing caps.
(6) Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear with No. 2 chain.
(7) Tie the No. 1 chain with a string as shown in the illustration.
NOTICE: Be careful not to drop anything inside the timing chain cover.
(f) Remove the No. 4 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) While pushing down the No. 3 chain tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.
(2) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing sprocket set bolt.
NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench.
(3) Separate the camshaft timing sprocket from the No. 4 camshaft.
(4) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
(5) Remove the 4 bearing caps and No. 4 camshaft.
(g) Remove the No. 3 chain tensioner.
(1) Remove the No. 3 chain tensioner bolt, No. 3 chain tensioner and camshaft timing sprocket.
(h) Remove the No. 3 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration.
(2) Remove the 4 bearing caps.
(3) Hold the No. 1 chain, and remove the No. 3 camshaft with camshaft timing gear and No. 2 chain.
(4) Tie the No. 1 chain with a string as shown in the illustration.
NOTICE: Be careful not to drop anything inside the timing chain cover.
(i) Remove the 24 valve lifters from the cylinder head LH and RH.
(j) Determine the size of the valve lifter to be installed according to the following formulas or charts.
(1) Using a micrometer, measure the thickness of the removed lifter.
(2) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
T: Thickness of removed lifter
A: Measured valve clearance
N: Thickness of new lifter
Intake: N = T + (A - 0.20 mm (0.00787 in.))
Exhaust: N = T + (A - 0.30 mm (0.0118 in.))
(3) Select a new lifter with a thickness as close as possible to the calculated value.
HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
Intake valve clearance (Cold): 0.15 to 0.25 mm (0.00591 to 0.00984 in.)
EXAMPLE: The 5.250 mm (0.2067 in.) shim is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) shim with a No. 46 lifter.
New Lifter Thickness:
Exhaust valve clearance (Cold): 0.29 to 0.39 mm (0.0114 to 0.0154 in.)
EXAMPLE: The 5.340 mm (0.210 in.) shim is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.210 in.) shim with a No. 48 lifter.
New Lifter Thickness:
(k) Install the No. 3 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) Align the mark link (yellow) with the timing mark (2-dot mark) of the camshaft timing gear shown in the illustration.
(2) Apply a light coat of engine oil to the thrust portions and journals of the No. 3 camshaft.
(3) Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.
(4) Set the No. 3 camshaft onto the cylinder head LH with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration.
(5) Apply a light coat of engine oil to the 4 bearing caps.
(6) Install the 4 bearing caps in their proper locations.
(7) Apply a light coat of engine oil to the threads of the 8 bearing cap bolts.
(8) Uniformly install the 8 bearing cap bolts in several steps in the order shown in the illustration.
Torque:
for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for 12 mm head 24 N*m (245 kgf*cm, 18 ft.*lbf)
(9) Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear.
(l) Install the No. 3 chain tensioner.
(1) While pushing in the tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.
(2) Temporarily install the camshaft timing sprocket and No. 3 chain tensioner, and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gear and sprocket.
(3) Apply a light coat of engine oil to the threads and under the head of the No. 3 chain tensioner bolt.
(4) Install the No. 3 chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(m) Install the No. 4 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) Apply a light coat of engine oil to the thrust portions and journals of the No. 4 camshaft.
(2) Apply a light coat of engine oil to the threads and under the head of the camshaft timing gear set bolt.
(3) Align the knock pin hole on the camshaft timing sprocket with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing sprocket.
(4) Temporarily install the camshaft timing gear set bolt.
(5) Install the 4 bearing caps in their proper locations.
(6) Apply a light coat of engine oil to the threads and under the heads of the 8 bearing cap bolts.
(7) Uniformly install the 8 bearing cap bolts in several steps in the order shown in the illustration.
Torque:
for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for 12 mm head 24 N*m (245 kgf*cm, 18 ft.*lbf)
(8) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(9) Remove the pin from the No. 3 chain tensioner.
(n) Install the No. 1 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) Align the mark link (yellow) with the timing mark (1-dot mark) of the camshaft timing gear as shown in the illustration.
(2) Apply a light of engine oil to the thrust portions and journals of the camshafts.
(3) Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.
(4) Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear.
(5) Apply a light coat of engine oil to the threads and under the head of the camshaft timing gear set bolt.
(6) Temporarily install the camshaft timing gear set bolt.
(7) Set the No. 1 camshaft onto the cylinder head RH with the cam lobes of the No. 1 cylinder facing downward as shown in the illustration.
(8) Apply a light coat of engine oil to the 4 bearing caps.
(9) Install the 4 bearing caps in their proper locations.
(10) Apply a light coat of engine oil to the threads and under the heads of the 8 bearing cap bolts.
(11) Uniformly install the 8 bearing cap bolts in several steps in the order shown in the illustration.
Torque:
for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for 12 mm head 24 N*m (245 kgf*cm, 18 ft.*lbf)
(12) Rotate the No. 1 camshaft clockwise using the hexagonal portion of the No. 1 camshaft so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap.
(13) Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear.
(14) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(o) Install the No. 2 chain tensioner.
(1) While pushing in the tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.
(2) Temporarily install the camshaft timing sprocket and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gear and sprocket.
(3) Apply a light coat of engine oil to the threads and under the head of the No. 2 chain tensioner bolt.
(4) Install the No. 2 chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(p) Install the No. 2 camshaft.
NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
(1) Apply a light coat of engine oil to the thrust portions and journals of the No. 2 camshaft.
(2) Set the No. 2 camshaft onto the cylinder head RH with the cam lobes of the No. 1 cylinder facing upward as shown in the illustration.
(3) Apply a light coat of engine oil to the 4 bearing caps.
(4) Install the 4 bearing caps in their proper locations.
(5) Apply a light coat of engine oil to the threads and under the heads of the 8 bearing cap bolts.
(6) Uniformly install the 8 bearing cap bolts in several steps in the order shown in the illustration.
Torque:
for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for 12 mm head 24 N*m (245 kgf*cm, 18 ft.*lbf)
(7) Rotate the No. 2 camshaft clockwise using a wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing sprocket.
(8) Apply a light coat of engine oil to the threads and under the head of the camshaft timing sprocket set bolt.
(9) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing sprocket set bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(10) Remove the pin from the No. 2 chain tensioner.
(q) Install the No. 1 chain tensioner.
(1) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
(2) While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.
(3) Apply a light coat of engine oil to the threads and under the heads of the 2 No. 1 chain tensioner bolts.
(4) Install the No. 1 chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(5) Remove the bar from the chain tensioner.
(6) Install a new gasket and the timing chain cover plate with the 4 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(7) Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark "0" of the timing chain cover.
(8) Check that the timing marks of the camshaft timing gears and sprockets are aligned with the timing marks of the bearing caps shown in the illustration.
9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
11. INSTALL SPARK PLUG
12. INSTALL IGNITION COIL ASSEMBLY
13. INSTALL INTAKE AIR SURGE TANK
(a) Install the intake air surge tank.
14. INSPECT IGNITION TIMING