Valve Clearance: Adjustments
NOTE: Inspect and adjust the valve clearance when the engine is cold.
1. Disconnect wire and clamp from generator.
2. Disconnect high-tension cord from cylinder head cover.
3. Remove cylinder head cover.
Remove the 4 cap nuts, seal washers, head cover and gasket.
4. 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 hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap.
If not, turn the crankshaft 1 revolution (360°).
5. 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: 0.15 - 0.25 mm (0.006 - 0.010 inch)
Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch)
(b) Turn the crankshaft one revolution (360°) and align its groove with timing mark "0" of the No. 1 timing belt cover.
(c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)).
6. Intake: Adjust valve clearance.
A. Remove intake camshaft.
B. Remove adjusting shim Remove the adjusting shim with a small screwdriver.
C. Determine the replacement adjusting shim size by following the Formula or Chart:
(a) Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
T: Thickness of removed shim.
A: Measured valve clearance.
N: Thickness of new shim.
N = T + (A - 0.20 mm (0.008 inch))
(c) Select a new shim with a thickness as close as possible to the calculated value.
Adjusting Shim Selection Chart (Intake):
NOTE: Shims are available in 16 sizes in increments of 0.05 mm (0.0020 inch), from 2.55 mm (1.0039 inch) to 3.30 mm (0.1299 inch).
D. Install new adjusting shim Place a new adjusting shim on the valve lifter.
E. Install intake camshaft.
F. Recheck valve clearance.
7. Exhaust: Adjust valve clearance.
A. Remove the adjusting shim.
(a) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve points upward.
(b) Position the notch of the valve lifter facing the front of the vehicle.
(c) Using Special Service Tool (SST) Valve Clearance Adjust Tool Set # 09248 - 55040 or (A) (Valve Lifter Press # 09248 - 05410), press down the valve lifter and place SST (B) Valve Lifter Stopper # 09248 - 05420 or equivalents between the camshaft and valve lifter. Remove SST (A).
NOTE:
^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration.
^ When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle.
^ The shape of the cam makes it difficult to insert SST (B), from the intake side to the No. 3 rear. For this shim, it is best approached from the exhaust side instead.
(d) Remove the adjusting shim with a small screwdriver and magnetic finger.
B. Determine the replacement adjusting shim size according to these Formula or Charts:
(a) Using a micrometer, measure the thickness of the removed shim.
(b) Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
T = Thickness of used shim.
A = Measured valve clearance.
N = Thickness of new shim.
N = T + (A - 0.30 mm (0.012 inch))
(c) Select a new shim with a thickness as close as possible to the calculated value.
Adjusting Shim Selection Chart (Exhaust):
NOTE: Shims are available in 16 sizes in increments of 0.05 mm (0.0020 inch), from 2.55 mm (1.0039 inch) to 3.30 mm (0.1299 inch).
C. Install a new adjusting shim.
(a) Place a new adjusting shim on the valve lifter.
(b) Using SST Valve Clearance Adjust Tool Set # 09248 - 55040 or (A) (Valve Lifter Press # 09248 - 05410), press down the valve lifter and remove SST (B) Valve Lifter Stopper # 09248 - 05420 or equivalents.
D. Recheck the valve clearance.
8. Install cylinder head cover.
9. Connect high-tension cord to cylinder head cover.
10. Connect wire and clamp to generator.