Valve Clearance Inspection And Adjustment

(Refer to Intake and Exhaust System - "AIR CLEANER ")

(Refer to Intake and Exhaust System - "SURGE TANK ")

(Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")

1. Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.

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2. Check that the mark of the camshaft timing sprockets are in straight line on the cylinder head surface as displayed in the image.

   If not, turn the crankshaft clockwise one revolution (360°).

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   NOTE:

   • Do not rotate engine counterclockwise.

1. With No. 1 cylinder at TDC inspect clearances only on the valves displayed in diagram below.

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   Measurement method.

   1. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
   2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting tappet.

   Valve Clearance: 

   Specification: 

   Engine Coolant Temperature: 20°C [68°F]

   Limit: 

   Intake: 0.10 - 0.30 mm (0.0039 - 0.0118 in.)

   Exhaust: 0.20 - 0.40 mm (0.0078 - 0.0157 in.)

2. Turn the crankshaft pulley clockwise one revolution (360°) and align the groove with timing mark "T" of the lower timing chain cover.
3. With No. 4 cylinder at TDC inspect clearances only the valves displayed in diagram below. (Refer to procedure step  1.)

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1. Set the No. 1 Cylinder to the TDC/Compression.
2. Remove the TIMING CHAIN . (Refer to Timing System in this procedure)
   NOTE:

   • Before removing the Timing Chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.

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3. Remove the fuel pump bracket (A).

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4. Remove the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).

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5. Remove the LH/RH camshaft assembly (A).

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6. Remove the tappets.
7. Measure the thickness of the removed tappet using a micrometer.

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8. Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

   T  : Thickness of removed tappet

   A  : Measured valve clearance

   N  : Thickness of new tappet

   Intake  : N = T + [A - 0.20 mm (0.0079 in.)]

   Exhaust  : N = T + [A - 0.35 mm (0.0113 in.)]

9. Select a new tappet with a thickness as close as possible to the calculated value.
   NOTE:

   • Shims are available in size-41 increments of 0.015 mm (0.0006 in.) from 3.00 mm (0.118 in.) to 3.600 mm (0.1417 in.)
10. Place a new tappet on the cylinder head.
    NOTE:

    • Apply Engine Oil at the selected tappet on the periphery and top surface.
11. Install the Intake And Exhaust Camshaft.
12. Install the Bearing Caps.

    (Refer to CYLINDER HEAD  Assembly)

13. Install the Timing Chain.

    (Refer to Timing System - "TIMING CHAIN ")

14. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing marks.

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15. Recheck the valve clearance.

    Valve Clearance (Engine Coolant Temperature: 20°C [68°F]) 

    [Specification]: 

    Intake: 0.17 - 0.23 mm (0.0067 - 0.0090 in.)

    Exhaust: 0.32 - 0.38 mm (0.0125 - 0.0149 in