Valve Clearance: Adjustments

INSPECTION

HINT: Inspect and adjust the valve clearance when the engine is cold.

1. DISCONNECT PS RESERVOIR.
2. REMOVE CYLINDER HEAD COVER.
a. Disconnect these cables and hoses:
- Accelerator cable from throttle body
- Accelerator cable from clamp on intake manifold
- Accelerator cable from clamp on generator bracket
- A/T throttle control cable from throttle body
- Positive Crankcase Ventilation (PCV) hose from air cleaner hose
- PCV hose from intake manifold

b. Disconnect the high-tension cords from the spark plugs.
c. Remove the 2 bolts, and disconnect the accelerator cable bracket from the intake manifold.





d. Disconnect the engine wire protector from the 2 mounting bolts of the No.2 timing belt cover in the sequence shown.





e. Remove the 4 nuts, grommets, cylinder head cover and gasket.

HINT: Arrange the grommets in the correct order, so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage due to reuse of the grommets in different positions.

3. SET NO.1 CYLINDER TO TOP DEAD CENTER (TDC)/COMPRESSION.





a. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the valve lifters on the No.1 cylinder are loose and valve lifters on the No.4 are tight.
If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
4. INSPECT VALVE CLEARANCE.





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

Valve clearance (Cold):
Intake: 0.19 - 0.29 mm (0.007 - 0.011 inch)
Exhaust: 0.28 - 0.38 mm (0.011 - 0.015 inch)

b. Turn the crankshaft 1 revolution (360°) and align the mark as above. (See procedure in step 3)





c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
5. ADJUST VALVE CLEARANCE.
a. Remove the adjusting shim.





- Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve points upward.
- Position the notch of the valve lifter facing the spark plug side.





- Using Special Service Tool (SST) (A), press down the valve lifter and place SST (A) between the camshaft and valve lifter. Remove SST (A).

SST 09248 - 55040 (09248 - 05410, 09248 - 05420)

HINT: Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration.





- Remove the adjusting shim with a small screwdriver and magnetic finger.





b. Determine the replacement adjusting shim size by following the Formula or Charts:
- Using a micrometer, measure the thickness of the removed shim.
- Calculate the thickness of a new shim so that the valve clearance comes within specified value.
T-Thickness of removed shim
A-Measured valve clearance
N-Thickness of new shim

Intake: N = T + (A - 0.24 mm (0.009 inch))
Exhaust: N = T + (A - 0.33 mm (0.013 inch))

- Select a new shim with a thickness as close as possible to the calculated value.

Adjusting Shim Selection Chart (Intake)





Adjusting Shim Selection Chart (Exhaust)





HINT: Shims are available in 17 sizes in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch).

c. Install a new adjusting shim.
- Place a new adjusting shim on the valve lifter.





- Using SST (A), press down the valve lifter and remove SST (B).

SST 09248 - 55040 (09248 - 05410, 09248 - 05420)
d. Recheck the valve clearance.

6. REINSTALL CYLINDER HEAD COVER.
a. Remove any old packing Formed In Place Gasket (FIPG) material.





b. Apply sea] packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826 - 00080 or equivalent
c. Install the gasket to the cylinder head cover.





d. Install the head cover with the 4 grommets and nuts. Uniformly tighten the nuts in several passes.

Torque: 44 Nm (33 ft. lbs.)

HINT: Install the grommets so that their markings are as shown in the illustration.





e. Install the engine wire protector to the 2 mounting bolts of the No.2 timing belt cover in the sequence shown.
f. Connect the high-tension cords to the spark plugs.
g. Install the accelerator cable bracket with the 2 bolts.
h. Connect these cables and hoses:
- Accelerator cable to throttle body
- Accelerator cable to clamp on intake manifold
- Accelerator cable to clamp on generator bracket
- A/T throttle control cable to throttle body
- PCV hose to air cleaner hose
- PCV hose to intake manifold

7. CONNECT PS RESERVOIR.