Valve Clearance: Adjustments

VALVE CLEARANCE

ADJUSTMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FRONT FENDER APRON SUB-ASSEMBLY RH
5. REMOVE NO. 1 ENGINE COVER
6. REMOVE IGNITION COIL ASSEMBLY
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

8. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b) Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.

9. CHECK VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

Standard Valve Clearance (Cold):

(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.
(b) Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.

(c) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

Standard Valve Clearance (Cold):

(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
10. ADJUST VALVE CLEARANCE
(a) Remove the No. 2 camshaft.
(b) Remove the camshaft.
(c) Remove the valve lifters.

(d) Using a micrometer, measure the thickness of the removed valve lifters.
(e) Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.

New Lifter Thickness:

CALCULATION EXAMPLE (Intake):
1. Measured intake valve clearance = 0.40 mm (0.0158 inch)
(Measured - Specification = Excess clearance)
(a) 0.40 mm (0.0158 inch) - 0.24 mm (0.0095 inch)= 0.16 mm (0.0063 inch)
2. Measured used lifter measurement = 5.250 mm (0.2067 inch)
3. New lifter thickness = 5.410 mm (0.2130 inch)
(Excess clearance + Used lifter thickness = Ideal new lifter)
(a) 0.16 mm (0.0063 inch) + 5.250 mm (0.2067 inch) = 5.410 mm (0.2130 inch)
4. Closest new lifter = 5.420 mm (0.2134 inch) - Select No. 42 lifter

(f) 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 to 5.740 mm (0.1992 to 0.2260 inch).
- The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 inch)

(g) Valve lifter selection chart (intake).

New Lifter Thickness:

Standard intake valve clearance (cold): 0.19 to 0.29 mm (0.0075 to 0.0114 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.

(h) Valve lifter selection chart (exhaust).

New Lifter Thickness:

Standard exhaust valve clearance (cold): 0.38 to 0.48 mm (0.0150 to 0.0189 inch)

EXAMPLE:
The 5.340 mm (0.2102 inch) lifter is installed, and the measured clearance is 0.430 mm (0.0169 inch).
Replace the 5.340 mm (0.2102 inch) lifter with a new No. 42 lifter.
(i) Install the selected valve lifter.
11. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.

(b) Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration.

(c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
(d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(e) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque:
No. 1 bearing cap 30 Nm (301 kgf-cm, 22 ft. lbs.)
No. 3 bearing cap 9.0 Nm (92 kgf-cm, 80 inch lbs.)
12. INSTALL NO. 2 CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b) 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.

(d) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(f) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque:
No. 2 bearing cap 30 Nm (301 kgf-cm, 22 ft. lbs.)
No. 3 bearing cap 9.0 Nm (92 kgf-cm, 80 inch lbs.)

(g) While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the valve lifter.

(h) Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.
13. INSTALL NO. 1 CHAIN TENSIONER
14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
15. INSTALL IGNITION COIL ASSEMBLY
16. CHECK FOR ENGINE OIL LEAKS
17. INSTALL NO. 1 ENGINE COVER
18. INSTALL FRONT FENDER APRON RH
19. INSTALL ENGINE UNDER COVER LH
20. INSTALL ENGINE UNDER COVER RH
21. INSTALL FRONT WHEEL RH