Valve Clearance: Adjustments

ADJUSTMENT
1. ADJUST VALVE CLEARANCE

NOTICE: Be sure not to turn the crankshaft without the chain tensioner.

(a) Turn the crankshaft clockwise 1 revolution (360°) and set the No.1 cylinder to the TDC/compression.
(b) Place paint marks on the timing chain and camshaft timing gear/sprocket.

(d) Remove the No.2 camshaft.
(1) Fix the camshaft with a wrench and then loosen the sprocket bolt.

NOTICE: Be careful not to damage the valve lifter.

(2) Uniformly loosen and remove the No.2 camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps.

(3) Raise the No.2 camshaft and remove it. Then remove the sprocket bolt.
(4) Remove the camshaft timing sprocket and the timing chain from the No.2 camshaft.
(5) Remove the camshaft timing sprocket from the timing chain.

(e) Remove the camshaft.
(1) Uniformly loosen and remove the camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps.
(2) Remove the camshaft.

(f) Tie the timing chain with a string.

NOTICE: Be careful not to drop anything inside the timing chain cover.

(g) Remove the valve lifters.

(h) Adjust the valve clearance.
(1) Using a micrometer, measure the thickness of the removed lifter.
(2) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

Valve Clearance:

EXAMPLE: (Intake)
Measured valve clearance = 0.44 mm (0.0173 inch)
0.44 mm (0.0173 inch) - 0.24 mm (0.0094 inch) = 0.20 mm (0.0079 inch)
(Measured - Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 inch) 0.20 mm (0.0079 inch) + 5.30 mm (0.2087 inch) = 5.50 mm (0.2165 inch)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 inch) = Shim No."50"

(3) Select a new lifter with a thickness as close as possible to the calculated values.

HINT:
^ Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).
^ Refer to valve lifter selection chart.

(i) Valve lifter selection chart (intake).

New Lifter Thickness (Part 1):

New Lifter Thickness (Part 2):

Intake valve clearance (Cold): 0.19 to 0.29 mm (0.008 to 0.011 inch)
EXAMPLE: The 5.250 mm (0.2067 inch) lifter is installed, and the measured clearance is 0.400 mm (0.0157 inch). Replace the 5.250 mm (0.2067 inch) lifter with a new No.42 lifter.

(j) Valve lifter selection chart (exhaust).

New Lifter Thickness (Part 1):

New Lifter Thickness (Part 2):

Exhaust valve clearance (Cold): 0.30 to 0.40 mm (0.012 to 0.016 inch)

EXAMPLE: The 5.340 mm (0.2102 inch) lifter is installed, and the measured clearance is 0.440 mm (0.0173 inch). Replace the 5.340 mm (0.2102 inch) lifter with a new No.44 lifter.

(k) Install the camshaft.
(1) Install the timing chain on the camshaft timing gear, with the paint mark aligned with the timing marks on the camshaft timing gear.

(2) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No.1 30 Nm (306 kgf-cm, 22 ft. lbs.)
Bearing cap No.3 9.0 Nm (92 kgf-cm, 80 inch lbs.)

(l) Install the No.2 camshaft.
(1) Put the No.2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.

(2) Raise the No.2 camshaft and temporarily tighten the sprocket bolt.

(3) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No.2 30 Nm (306 kgf-cm, 22 ft. lbs.)
Bearing cap No.3 9.0 Nm (92 kgf-cm, 80 inch lbs.)

(4) Fix the camshaft with a wrench, then tighten the sprocket bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the valve lifter.

(m) Check that the timing chain paint marks are aligned with the camshaft timing sprocket timing mark and the camshaft timing gear timing mark. Also check the alignment of the pulley groove and chain cover timing mark 0.

(n) Install the chain tensioner.
(1) Raise the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.

(2) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger.

(3) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.

(4) Turn the crankshaft clockwise, and check that the chain tensioner slipper is pushed by the plunger.