VALVE CLEARANCE INSPECTION/ADJUSTMENT

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VALVE CLEARANCE INSPECTION

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.

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•  If it is not within the specification, replace the tappet and adjust the valve clearance to the standard clearance. (See VALVE CLEARANCE ADJUSTMENT.)
Standard valve clearance [when cold]
IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}
Note
•  When replacing the tappet, select the tappet according to the measured value and note down the measured value.

3.  Rotate the crankshaft clockwise 360° so that the No.4 piston is at the TDC of the compression stroke.

4.  Measure the valve clearance at B in the figure.

•  If it is not within the specification, replace the tappet and adjust the valve clearance to the standard clearance. (See VALVE CLEARANCE ADJUSTMENT.)
Standard valve clearance [when cold]
IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}
Note
•  When replacing the tappet, select the tappet according to the measured value and note down the measured value.


VALVE CLEARANCE ADJUSTMENT

1.  Remove the engine front cover lower blind plug.

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2.  Remove the engine front cover upper blind plug.

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3.  Remove the cylinder block lower blind plug and install the SST.

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4.  Rotate the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke. (The position crank weight contacts the SST.)

5.  Loosen the timing chain using the following procedure:

Note
•  Verify the ratchet position using the mirror before servicing. If the ratchet is not tilted, remove the engine front cover before performing the procedure.
•  If the timing chain tension cannot be released with the ratchet tilted, remove the engine front cover before performing the procedure.

Ratchet unlock position

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(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.)
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(2)  Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.
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(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.
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(4)  Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.
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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.
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(5)  Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.
Note
•  The ratchet has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.
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•  If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.

6.  Secure the exhaust camshaft using a wrench on the cast hexagon and loosen the camshaft sprocket bolt.

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7.  Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.

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Caution
•  Perform the work carefully so that the washer does not drop out.

8.  Remove the OCV.

9.  Loosen the camshaft cap bolts in two or three passes in the order shown in the figure, and remove the camshaft bearing caps.

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Note
•  The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.

10.  Remove the camshafts for intake and exhaust sides.

11.  Remove the tappet.

12.  Select and install the suitable tappet according to the result of valve clearance inspection.

Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance
Standard valve clearance [when cold]
IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}
Caution
•  Do not use a removed tappet on another vehicle.
•  If a tappet is reused, measure the thickness of the tappet and select the tappet in which the valve clearance is within the specification.
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Tappet specification

Identification mark

Thickness (mm {in})

Tolerance (mm {in})
000
3.000 {0.1181}
±0.0125 {0.000492}
025
3.025 {0.1191}
±0.0125 {0.000492}
050
3.050 {0.1201}
±0.0125 {0.000492}
075
3.075 {0.1211}
±0.0125 {0.000492}
100
3.100 {0.1220}
±0.0125 {0.000492}
122
3.122 {0.1229}
±0.0100 {0.000394}
142
3.142 {0.1237}
±0.0100 {0.000394}
162
3.162 {0.1245}
±0.0100 {0.000394}
182
3.182 {0.1253}
±0.0100 {0.000394}
202
3.202 {0.1261}
±0.0100 {0.000394}
222
3.222 {0.1269}
±0.0100 {0.000394}
242
3.242 {0.1276}
±0.0100 {0.000394}
262
3.262 {0.1284}
±0.0100 {0.000394}
282
3.282 {0.1292}
±0.0100 {0.000394}
302
3.302 {0.130}
±0.0100 {0.000394}
322
3.322 {0.1308}
±0.0100 {0.000394}
342
3.342 {0.1316}
±0.0100 {0.000394}
362
3.362 {0.1324}
±0.0100 {0.000394}
382
3.382 {0.1331}
±0.0100 {0.000394}
402
3.402 {0.1339}
±0.0100 {0.000394}
422
3.422 {0.1347}
±0.0100 {0.000394}
442
3.442 {0.1355}
±0.0100 {0.000394}
462
3.462 {0.1363}
±0.0100 {0.000394}
482
3.482 {0.1371}
±0.0100 {0.000394}
502
3.502 {0.1379}
±0.0100 {0.000394}
522
3.522 {0.1387}
±0.0100 {0.000394}
542
3.542 {0.1394}
±0.0100 {0.000394}
562
3.562 {0.1402}
±0.0100 {0.000394}
582
3.582 {0.1410}
±0.0100 {0.000394}
602
3.602 {0.1418}
±0.0100 {0.000394}
625
3.625 {0.1427}
±0.0125 {0.000492}
650
3.650 {0.1437}
±0.0125 {0.000492}
675
3.675 {0.1447}
±0.0125 {0.000492}
700
3.700 {0.1457}
±0.0125 {0.000492}
725
3.725 {0.1467}
±0.0125 {0.000492}

13.  Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.

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14.  Install the camshaft with No.1 cylinder cam aligned at TDC of the compression stroke.

15.  Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure. However, do not apply it to the end journal of the intake camshaft.

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16.  Carefully apply sealan agent (Loctite 518 or 962) to the area indicated in the figure so that it does not leak into the sliding part then, apply the gear oil (SAE No. 90 or equivalent) to the journal.

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Note
•  To prevent engine oil leakage, apply sealant to the rear camshaft cap on the intake side and seal the journal.
Sealan agent bead width
1.0 mm {0.039 in}

17.  Install the camshaft bearing cap and tighten the camshaft bearing cap bolts in two passes in the order shown in the figure.

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Tightening procedure
(1) 5.0—9.0 N·m {51.0—91.7 kgf·cm,44.3—79.6 in·lbf}
(2) 14.0—17.0 N·m {1.5—1.7 kgf·m, 10.4—12.5 ft·lbf}

18.  Install the OCV.

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Tightening torque
8.0—11.5 N·m {82—117 kgf·cm, 71—101 in·lbf}

19.  Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

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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 bolt at this stage. Verify the valve timing before performing the bolt tightening.

20.  Install the SST on the camshaft as shown in the figure.

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21.  Remove the bolt (M6 X 1.0 length 25—35 mm {0.99—1.37 in}) from the engine front cover upper blind plug and apply tension to the timing chain.

22.  Rotate the crankshaft clockwise and verify that the No.1 piston is at TDC of the compression stroke.

23.  Secure the exhaust camshaft using a wrench on the cast hexagon and tighten the sprocket bolt.

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Tightening torque
69—75 N·m {7.1—7.6 kgf·m, 50.9—55.3 ft·lbf}

24.  Remove the SST from the camshaft.

25.  Remove the SST installed in the cylinder block lower blind plug hole.

26.  Rotate the crankshaft clockwise two turns and inspect the valve timing.

•  If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 20.

27.  Apply silicone sealant and install the engine front cover upper blind plug.

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Note
•  Install the engine front cover upper blind plug before the applied silicone sealant starts to harden.
Tightening torque
8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf}

28.  Install the cylinder block lower blind plug.

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Tightening torque
18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}

29.  Install a new engine front cover lower blind plug.

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Tightening torque
10.0—14.0 N·m {102.0—142.7 kgf·cm, 88.6—123.9 in·lbf}