Valve Clearance: Adjustments
ADJUSTMENT1. REMOVE ENGINE UNDER COVER RH
2. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 3 bolts, the nut and the cylinder head cover No. 2.
3. REMOVE IGNITION COIL ASSY
a. Remove the 3 bolts and the nut, and disconnect the 4 connectors, and remove the 4 ignition coils.
4. REMOVE WIRE HARNESS CLAMP
a. Disconnect the engine wire harness.
b. Remove the bolt and wiring harness clamp bracket.
5. DISCONNECT SUCTION HOSE SUB-ASSY
a. Remove the 2 nuts installing the suction hose sub-assy.
b. Disconnect the suction hose sub-assy.
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Disconnect the fuel hose clamp and 2 PCV hoses from the cylinder head cover.
b. Remove the 2 nuts, bolt and disconnect the No. 3 ventilation hose from the No. 1 ventilation pipe.
c. Disconnect the ventilation No. 1 tube and gasket.
d. Remove the 8 bolts, wire harness protector, cylinder head cover and gasket.
e. Remove the O-ring from the cylinder head cover.
7. REMOVE FAN AND GENERATOR V-BELT
a. Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and put back the drive belt tensioner little by little and fix it quietly.
8. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSY RH
a. Set the jack to the engine.
HINT: Place a wooden block between the jack and engine.
b. Remove the 5 bolts, 2 nuts and engine mounting insulator sub-assy RH.
9. SET NO. 1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
b. 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.
10. REMOVE V-RIBBED BELT TENSIONER ASSY
HINT: Handle a jack up and down to remove the bolt.
11. INSPECT VALVE CLEARANCE
a. Check only the valves indicated.
1 Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
2 Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
Valve clearance (Cold)
b. Turn the crankshaft 1 revolution (360°) and set No. 4 cylinder to TDC/compression.
c. Check only the valves indicated.
1 Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
2 Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
Valve clearance (Cold)
12. ADJUST VALVE CLEARANCE
a. Set the SST.
1 Turn the crankshaft so that the related rocker arm,where the valve clearance is adjusted, is fully pushed down.
NOTICE: Remove the spark plug and take off the compression.
2 Insert SST into the plug tube.
SST 09248-77010 (09248-07010)
NOTICE:
- SST cannot be inserted unless the set screw is loosened.
- Make sure that the camshaft is in the same condition as step (1).
3 Operate the lever so that SST's seat surface comes to contact with the valve retainer and lock them with the set screw.
NOTICE:
- Clearance between the valve retainer and SST's seat surface is not allowed.
- Care should be taken not to make clearance when inserting SST, since a presence of clearance may unlock the keeper.
4 lock the set screw on the plug tube side of SST.
5 Rotate the crankshaft so that the camshaft is positioned as shown in the illustration.
NOTICE:
- Pay attention to the direction of the rotation to prevent the nose of the camshaft from interfering with the SST's shaft.
- Do not rotate the crankshaft excessively.
b. Remove the adjusting shim.
1 Lift the rocker arm to make a room and remove the adjusting shim using SST
SST 09248-77010 (09248-07010)
N0TICE: Do not remove SST in the condition that adjusting shim is removed.
HINT:
- Setting SST from the right makes the removal easy.
- If there is not enough room, reset SST
2 Determine the size of the replaced shim according to there Formula or Charts:
- Using a dial indicator, measure the thickness of the removed shim.
- Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
Intake: A = B + (C - 0.13 mm (0.005 inch))x 1.5
Exhaust: A = B + (C - 0.27 mm (0.011 inch)) x 1.5
HINT: Shim are available in 41 sizes in increments of 0.020 mm (0.0008 inch), from 2.000 mm (0.0787 inch) to 2.800 mm (0.1102 inch).
c. Lift the rocker arm to make a room and use SST, install the adjusting shim.
HINT:
- Setting SST from the right makes the removal easy.
- To remove SST from the adjusting shim, it is advisable to push down the rocker arm.
d. Turn the crankshaft so that the related rocker arm, where the valve clearance is adjusted, is fully pushed down.
NOTICE:
- Pay attention to the direction of the rotation to prevent the nose of the camshaft from interfering with the SST's shaft.
- Do not rotate the crankshaft excessively.
e. After loosening the 2 set screws of SST, remove SST itself.
SST 09248-77010 (09248-07010)
13. INSTALL V-RIBBED BELT TENSIONER ASSY
Torque:
Nut 29 Nm (296 kgf-cm, 21 ft. lbs.)
Bolt 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
14. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSY RH
a. Install the engine mounting insulator sub-assy RH with the 5 bolts and the 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
15. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Remove any old packing (FIPG) material.
HINT: When FIPG on the head cover gasket side cannot be eliminated completely, replace the gasket.
b. Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the cylinder head cover gasket to the cylinder head cover.
HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.
d. Install the new spark plug tube gasket and a new O-ring to the cylinder head cover.
e. Install the cylinder head cover and wire harness protector with the 8 bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
f. Connect the PCV hoses to the cylinder head cover.
g. Install a new gasket and No. 1 ventilation pipe with 2 nuts and bolt.
Torque:
Nut 10 Nm (102 kgf-cm, 7 ft. lbs.)
Bolt 24 Nm (245 kgf-cm, 18 ft. lbs.)
h. Connect the No. 3 ventilation hose to the No. 1 ventilation pipe.
16. INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
17. INSTALL WIRE HARNESS CLAMP
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
18. INSTALL IGNITION COIL ASSY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
19. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
20. INSPECT OIL LEAK