Valve Clearance Adjustment

Remove the engine front cover lower blind plug.

Fig 1: Identifying Engine Front Cover Lower Blind Plug
Remove the engine front cover upper blind plug.

Fig 2: Identifying Engine Front Cover Upper Blind Plug
Remove the cylinder block lower blind plug, and install the SST .
Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the compression stroke. (Until the counterweight contacts SST and stops.)
Loosen the timing chain using the following procedure:

Fig 3: Identifying SST (303-507)
1. Insert a suitable bolt (M6 X 1.0, length 25-35 mm {0.99-1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)
  
  Fig 4: Inserting Suitable Bolt (M6 X 1.0, Length 25-35 mm [0.99-1.3 in]) Into Engine Front Cover Upper Blind Plug
2. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.
3. Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.
  
  Fig 5: Applying Force Counterclockwise To Facilitate Unlocking Chain Tensioner Ratchet
  
  Fig 6: Unlocking Chain Tensioner Ratchet
4. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.
  
  Fig 7: Applying Force In Direction Of Engine Rotation To Increase Tension On Chain
  NOTE:
  - The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.
  NOTE:
  - The racket has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.
5. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.
  
  Fig 8: Applying Force To Exhaust Camshaft In Direction Of Engine Rotation
  
  Fig 9: Securing Tensioner Arm With Rack Compressed
  - If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.
Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket installation bolt.
CAUTION:
- Perform the work carefully so that the washer does not drop out.
Fig 10: Holding Camshaft Sprocket On Cast Hexagon
Remove the exhaust camshaft sprocket installation bolt, exhaust camshaft sprocket, and washer as a single unit.

Fig 11: Removing Exhaust Camshaft Sprocket Installation Bolt, Exhaust Camshaft Sprocket, And Washer
Remove the OCV.
NOTE:
- The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.
Fig 12: Identifying OCV
Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.

Fig 13: Identifying Camshaft Cap Bolt Loosening Order

G08575780

Remove the camshafts for the intake and exhaust sides.
Remove the tappet.
Install an appropriate tappet based on the results of the valve clearance inspection.
Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance

Standard valve clearance [Engine cold]

IN: 0.22-0.28 mm {0.009-0.011 in}

EX: 0.27-0.33 mm {0.011-0.012 in}
Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST .)
Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.

Fig 14: Applying Gear Oil (SAE No.90 Or Equivalent) To Each Journal Of Cylinder Head

G08575781

Install the camshaft with No.1 cylinder aligned with the TDC position.
Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.
Temporarily tighten the camshaft cap bolts evenly in 2-3 steps.

Fig 15: Applying Gear Oil (SAE No.90 Or Equivalent) To Each Journal Of Camshaft
Tighten the camshaft cap bolts in the order shown in the following two steps.
Tightening procedure
1. 5.0-9.0 N.m {51-91 kgf.cm, 45-79 in.lbf}
2. 14-17 N.m {1.5-1.7 kgf.m, 11-12 ft.lbf}
  
  Fig 16: Identifying Camshaft Cap Bolt Tightening Order
Install the OCV.
Tightening torque

8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
CAUTION:
- Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer.
- Do not tighten the camshaft sprocket installation bolt at this stage. Verify the valve timing before performing the bolt tightening.
Fig 17: Identifying OCV
Install the exhaust camshaft sprocket installation bolt, exhaust camshaft sprocket, and a new washer as a single unit.

Fig 18: Identifying Exhaust Camshaft Sprocket Installation Bolt, Exhaust Camshaft Sprocket, And Washer
Install the SST on the camshaft as shown in the figure.
Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25-35mm {1.0-1.3 in}) , and apply tension to the timing chain.
Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket installation bolt.
Remove the SST from the camshaft.
Remove the SST installed in the cylinder block lower blind plug hole.

Fig 19: Installing SST (303-465) On Camshaft
Rotate the crankshaft clockwise two turns and inspect the valve timing.
- If not aligned, repeat the procedure from 21.
Install the cylinder block lower blind plug.
Tightening torque

18-22 N.m {1.9-2.2 kgf.m, 14-16 ft.lbf}

Fig 20: Identifying Cylinder Block Lower Blind Plug
Apply the silicone sealant and install the engine front cover upper blind plug.
Tightening torque

8.0-11.5 N.m {82-117 kgf.cm, 71-101 in.lbf}

Fig 21: Identifying Engine Front Cover Upper Blind Plug
Install a new engine front cover lower blind plug.
Tightening torque

10-14 N.m {102-142 kgf.cm, 89-123 in.lbf}

Fig 22: Identifying Engine Front Cover Lower Blind Plug