Valve Clearance: Adjustments

Valve Clearance Adjustment

Special Service Tools






Tappet hold-down tool

303-540





Tappet hold-down tool adaptor

303-540/02





Fan nozzle - air gun

303-590

CAUTION: Rotating the crankshaft in a counterclockwise direction may cause engine damage. Crankshaft journals are directionally machined. Rotating the crankshaft counterclockwise can raise burrs on bearing surfaces, reducing engine life.

CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or valve clearance will be incorrect.
1 Disconnect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect
2 Check the valve clearances. For additional information, refer to Valve Clearance Check Testing and Inspection




3 Rotate the engine clockwise to position the camshaft lobe away from the valve tappet.




4 Install the special tool 303-540, to the cylinder head.
- Tighten the 2 bolts to 10 Nm




5
CAUTION: Do not rotate the crankshaft while the special tool 303-540/02 is attached to 303-540.
Attach the special tool 303-540/02 to 303-540.
- Secure with the 2 wing nuts.




6 Position the special tool to the tappet as shown.




7 Using the special tool, compress the valve spring.




8
CAUTION: Do not use a magnet to remove shims. Failure to follow these instructions may result in damage to the vehicle.
NOTE:
Use the following formula to calculate the required shim thickness. Original shim thickness + measured shim clearance - desired clearance = required shim thickness.
Remove, clean and measure the shim.
- Surround the immediate working area with a cloth, to retain any loose shims displaced by the compressed air.
- Use the special tool 303-590, aimed at the edge of the shim, to lift it from the tappet. Note the position of each one.
9
CAUTION: Shims must be fitted with the size markings facing the tappet, not the camshaft.
CAUTION: Do not use a magnet to install shims. Failure to follow these instructions may result in damage to the vehicle.
Install the new shim.
- Clean the components.
- Lubricate the shim with clean engine oil.
- Release and remove the special tools as required.





10 Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.

11 Repeat the above procedure for the remaining valves.