Valve Clearance: Adjustment

1. Remove the 2 nuts, 2 clips and cylinder head cover.

Fig 1: Removing Cylinder Head Cover No. 2

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1. Remove the 5 clamps from the 5 clamp brackets.
2. Disconnect the 4 ignition coil connectors.
   Fig 2: Disconnecting Ignition Coil Connectors

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3. Remove the bolt and nut installing the engine wire.

Fig 3: Disconnecting Engine Wire

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1. Remove the 4 bolts and 4 ignition coils.

Fig 4: Removing Ignition Coils

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1. Disconnect the ventilation hose from the cylinder head cover.

Fig 5: Disconnecting Ventilation Hose From Cylinder Head Cover

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1. Disconnect the ventilation hose from the cylinder head cover.

Fig 6: Disconnecting Ventilation Hose No. 2

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1. Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp brackets and cylinder head cover.

Fig 7: Removing Cylinder Head Cover

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1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
2. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.

HINT:

If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

Fig 8: Checking Point Marks Of Camshaft Timing Sprocket And VVT Timing Sprocket On Timing Chain Cover Surface

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1. Check only the valves indicated.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   2. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

   Valve clearance (Cold): 

   Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.) 

   Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 

2. Turn the crankshaft 1 revolution (360 °) and set No. 4 cylinder to TDC/compression.
   Fig 9: Setting No. 1 Cylinder To TDC/Compression Position

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3. Check only the valves indicated.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   2. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

   Valve clearance (Cold): 

   Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.) 

   Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 

Fig 10: Setting No. 4 Cylinder To TDC/Compression Position

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1. Turn the drive belt tensioner clockwise to relieve tension on the belt, and then remove the belt.
2. Carefully return the tensioner to the unloaded position.

Fig 11: Removing Fan And Generator V Belt

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1. Remove the PS oil pump reservoir and put it aside.
2. Place a wooden block between the jack and engine, and set the jack, then remove the 4 bolts, the 2 nuts and engine mounting insulator RH.

Fig 12: Placing Wooden Block Between Jack And Engine

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Fig 13: Removing Engine Mounting Insulator RH

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1. Remove the bolt, nut and V-ribbed belt tensioner.

HINT:

Handle a jack up and down to remove the bolt.

Fig 14: Removing V-Ribbed Belt Tensioner

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1. Set the No. 1 cylinder to the TDC/compression.
2. Place match marks on the timing chain and camshaft timing sprockets.
   Fig 15: Placing Match Marks On Timing Chain And Camshaft Timing Sprockets

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3. Remove the 2 nuts and chain tensioner.
   Fig 16: Removing Chain Tensioner

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4. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt.
   NOTE: Be careful not to damage the valve lifter.
   Fig 17: Loosening Camshaft Timing Gear Set Bolt

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5. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the order as shown in the illustration in several passes, and remove the caps.
   Fig 18: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts On No. 2 Camshaft

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6. Remove the camshaft timing gear as shown in the illustration.
   Fig 19: Removing Camshaft Timing Gear

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7. Loosen the camshaft bearing cap bolts on camshaft in the order as shown in the illustration in several passes, and remove the caps.
   Fig 20: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts

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8. Remove the camshaft with holding the timing chain.
   Fig 21: Removing Camshaft With Holding Timing Chain

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9. Tie the timing chain with a string as shown in the illustration.
   NOTE: Be careful not to drop anything inside the timing chain cover.
   Fig 22: Tie Timing Chain With String

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10. Remove the valve lifters.
11. Using a micrometer, measure the thickness of the removed lifter.
12. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
    VALVE LIFTERS CLEARANCE
    
    

    A	Thickness of new lifter
    B	Thickness of used lifter
    C	Measured valve clearance

    Valve clearance: 

    Intake A = B + (C - 0.20 mm (0.0079 in.) 

    Exhaust A = B + (C - 0.30 mm (0.0118 in.) 

    HINT:

    • Select a new lifter with a thickness as close as possible to the calculated values.
    • Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
    Fig 23: Measuring Thickness Of Removed Lifter

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13. As shown in the illustration, install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprocket.
    Fig 24: Installing Timing Chain On Camshaft Timing Gear

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14. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.

    Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

    Fig 25: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts

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15. Put the camshaft No.2 on the cylinder head with the painted links of the chain aligned with the timing mark on the camshaft timing sprocket.
    Fig 26: Putting Camshaft No. 2 On Cylinder Head With Painted Links Of Chain Aligned With Timing Mark On Camshaft Timing Sprocket

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16. Tighten the camshaft timing gear set bolt temporarily.
    Fig 27: Tightening Camshaft Timing Gear Set Bolt

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17. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.

    Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

18. Install the bearing cap No. 1.

    Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) 

    Fig 28: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts On No. 2 Camshaft

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19. Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt.

    Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 

    NOTE: Be careful not damage the valve lifter.
    Fig 29: Tightening Camshaft Timing Gear Set Bolt

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20. Check the match marks on the timing chain and camshaft timing sprockets, and then the alignment of the pulley groove with timing mark of the chain cover as shown in the illustration.
    Fig 30: Aligning Match Marks On Timing Chain And Camshaft Timing Sprockets

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21. Install chain tensioner.
    1. Check the O-ring is clean, and set the hook as shown in the illustration.
       Fig 31: Setting Hook

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    2. Apply engine oil to the chain tensioner and install it with the 2 nuts.

       Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

       NOTE: When installing the tensioner, set the hook again if the hook release the plunger.
       Fig 32: Installing Chain Tensioner

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    3. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
       Fig 33: Disconnecting Plunger Knock Pin From Hook

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    4. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

    HINT:

    If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.

    Fig 34: Turning Crankshaft Clockwise And Checking That Slipper Pushed By Plunger

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1. Install the V-ribbed belt tensioner with the nut and bolt.

   Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) for Nut 

   69 N.m (704 kgf.cm, 51 ft.lbf) for Bolt 

Fig 35: Installing V-Ribbed Belt Tensioner Assy

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1. Install engine mounting insulator RH with the 4 bolts and the 2 nuts.

   Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

Fig 36: Installing Engine Mounting Insulator Sub-Assy RH

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1. Remove any old packing (FIPG) material.
2. Apply seal packing to 2 locations as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not put into engine oil 2 hours after installing.
   Fig 37: Applying Seal Packing

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3. Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes.

   Torque: A 11 N.m (112 kgf.cm, 8 ft.lbf) 

   B 9.0 N.m in (92 kgf.cm, 80 in.lbf) 

Fig 38: Installing Cylinder Head Cover

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1. Install the 4 ignition coils with the 4 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

Fig 39: Installing Ignition Coil Assy

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1. Install the engine wire with the bolt and nut.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

Fig 40: Installing Engine Wire

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1. Install the cylinder head cover with the 2 nuts and 2 clips.

   Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

Fig 41: Installing Cylinder Head Cover No. 2

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