Valve Clearance: Adjustments
VALVE CLEARANCE ADJUSTMENT [LF]1. Remove the battery and battery tray.
2. Remove the plug hole plate.
3. Remove the air cleaner.
4. Disconnect the ventilation hose.
5. Remove the front suspension tower bar (joint).
6. Remove the CMP sensor.
7. Disconnect the OCV connector.
8. Disconnect the P/S pressure switch connector.
9. Remove the ignition coils.
10. Remove the cylinder head cover.
11. Remove the drive belt.
12. Remove the engine front cover lower blind plug.
13. Remove the engine front cover upper blind plug.
14. Remove the cylinder block lower blind plug.
15. Install the SST as shown.
16. Turn the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position.
17. Loosen the timing chain.
1) Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
2) Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain.
3) Placing the suitable bolt (M6 X 1.0 length 25 mm-35 mm (0.99 in-1.37 in) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
18. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.
19. Remove the exhaust camshaft sprocket.
20. Loosen the camshaft cap bolts in several passes in the order shown.
Note
^ The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. Do not mix the caps.
21. Remove the camshafts.
22. Remove the tappet.
23. Select proper adjustment tappet.
New adjustment tappet
= Removed tappet thickness + Measured valve clearance- Standard valve clearance (IN: 0.25 mm (0.0098 in), EX: 0.30 mm (0.0118 in)
Valve clearance [Engine cold]
IN: 0.22-0.28 mm (0.0087-0.0110 in)
EX: 0.27-0.33 mm (0.0107-0.0129 in)
24. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.
25. Install the camshaft with No.1 cylinder camshaft lobes aligned with the TDC position.
26. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.
27. Tighten the camshaft cap bolt with 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).
28. Install a new washer.
29. 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.
30. Install the SST to the camshaft as shown.
31. Remove the M6 X 1.0 bolt (length 25 mm-35 mm (0.99 in-1.37 in) from the engine front cover to apply tension to the timing chain.
32. Turn the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position.
33. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.
34. 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)
35. Remove the SST from the camshaft.
36. Remove the SST from the block lower blind plug.
37. Rotate the crankshaft clockwise two turns until the TDC position.
^ If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 16.
38. Apply silicone sealant to the engine front cover upper blind plug.
39. Install the engine front cover upper blind plug.
Tightening torque 8.0-11.5 N-m (82-117 kgf-cm, 71-101 ft-lbf)
40. 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)
41. Install the new engine front cover lower blind plug.
Tightening torque: 10-14 N-m (102-142 kgf-cm, 89-123 in-lbf)
42. Install the drive belt.
43. Measure the valve clearance.
1) Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
2) Measure the valve clearance at A in the figure.
^ If the valve clearance is out of the specification, adjust it.
Note
^ Make sure to note down the measured values for choosing the suitable replacement tappets.
Valve clearance [Engine cold]
IN: 0.22-0.28 mm (0.0087-0.0110 in)
EX: 0.27-0.33 mm (0.0107-0.0129 in)
3) Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke.
4) Measure the valve clearance at B in the figure.
^ If the valve clearance is out of the specification, adjust it.
Note
^ Make sure to note down the measured values for choosing the suitable replacement tappets.
Valve clearance [Engine cold]
IN: 0.22-0.28 mm (0.0087-0.0110 in)
EX: 0.27-0.33 mm (0.0107-0.0129 in)
44. Install the cylinder head cover.
45. Install the ignition coils.
46. Connect the OCV connector.
47. Install the CMP sensor.
48. Install the front suspension tower bar (joint).
49. Connect the ventilation hose.
50. Install the air cleaner.
51. Install the plug hole plate.
52. Install the battery and battery tray.