Inspect and adjust the valve clearance when the engine is
cold (Engine coolant temperature : 20°C(68°F)) and cylinder head is
installed on the cylinder block.
1.
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
2.
Set No.1 cylinder to TDC/compression.
(1)
Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.
(2)
Check that the mark of the camshaft timing sprockets are in
straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft clockwise one revolution (360°).
Do not rotate engine counterclockwise.
3.
Inspect the valve clearance.
(1)
With No.1 cylinder at TDC inspect clearances only on the valves shown in diagram below.
Measurement method.
a.
Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
b.
Record the out-of-specification valve clearance measurements.
They will be used later to determine the required replacement adjusting
tappet.
Valve clearance (Engine coolant temperature : 20°C [68°F])
[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
(2)
Turn the crankshaft pulley clockwise one revolution (360°)
and align the groove with timing mark "T" of the lower timing chain
cover.
(3)
With No.4 cylinder at TDC inspect clearances only the valves shown in diagram below. (Refer to procedure step 1.)
4.
Adjust the intake and exhaust valve clearance.
(1)
Set the No.1 cylinder to the TDC/compression.
(2)
Remove the timing chain.
Before removing the timing chain, mark the RH/LH timing chain
with an identification based on the location of the sprocket because
the identification mark on the chain for TDC (Top Dead Center) can be
erased.
(3)
Remove the fuel pump bracket (A).
(4)
Remove the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).
(5)
Remove the LH/RH camshaft assembly (A).
(6)
Remove the tappets.
(7)
Measure the thickness of the removed tappet using a micrometer.
(8)
Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A - 0.30mm (0.0118in.)]
(9)
Select a new tappet with a thickness as close as possible to the calculated value.
Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm (0.1417in.)
(10)
Place a new tappet on the cylinder head.
Apply engine oil at the selected tappet on the side and top surface.
(11)
Install the intake and exhaust camshaft.
(12)
Install the bearing caps.
(Refer to Cylinder Head Assembly - "CVVT & Camshaft")
(13)
Install the timing chain.
(Refer to Timing System - "Timing Chain")
(14)
Turn the crankshaft two turns in the operating direction
(clockwise) and realign crankshaft sprocket and camshaft sprocket timing
marks.
(15)
Recheck the valve clearance.
Valve clearance (Engine coolant temperature : 20°C [68°F])
Removal
[LH]
1.
Remove the Intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
2.
Remove the high pressure fuel pump.
(Refer to Fuel System - "High Pressure Fuel P ...
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Components and Components Location
Cylinder Head Cover Repair procedures