VALVE CLEARANCE(w/ DPF) ADJUSTMENT

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    Click here

  4. DISCONNECT NO. 1 FUEL HOSE SUB-ASSEMBLY


    1. A0047H3

      Slide the hose clip and disconnect the No. 1 fuel hose sub-assembly from the No. 2 nozzle leakage pipe.

  5. DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

    A00489D

    1. Slide the hose clip and disconnect the nozzle leakage pipe assembly from the No. 2 nozzle leakage pipe.

    2. Disengage the clamp to separate the nozzle leakage pipe assembly from the hose clamp.

  6. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

    Click here

  7. REMOVE NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  8. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  9. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  10. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  11. REMOVE SENSOR BRACKET

    Click here

  12. SEPARATE ENGINE WIRE (for LHD)


    1. A0047RK

      Disconnect the 6 connectors as shown in the illustration.

    2. Separate the wiring harness clamp bracket from the cylinder head cover sub-assembly.

    3. Disengage the 2 clamps and separate the engine wire as shown in the illustration.

  13. SEPARATE ENGINE WIRE (for RHD)


    1. A004A0Y

      Disconnect the 6 connectors as shown in the illustration.

    2. Separate the wiring harness clamp bracket from the cylinder head cover sub-assembly.

    3. Disengage the clamp and separate the engine wire as shown in the illustration.

  14. REMOVE WIRING HARNESS CLAMP BRACKET (for LHD)


    1. A0046XE

      Disconnect the vacuum hose from the wiring harness clamp bracket.

    2. Remove the 2 bolts and 2 wiring harness clamp brackets from the cylinder head cover sub-assembly.

  15. REMOVE WIRING HARNESS CLAMP BRACKET (for RHD)


    1. A0047BF

      Disconnect the vacuum hose from the wiring harness clamp bracket.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  17. CHECK VALVE CLEARANCE


    1. Set the No. 1 cylinder to TDC/Compression.


      1. Turn the crankshaft damper sub-assembly until the grooves of the crankshaft damper sub-assembly and timing chain cover assembly are aligned.

      2. A0048HPE10
        Text in Illustration
        *a Timing Mark
        *b TDC Mark

        Check that the timing mark of the camshaft timing sprocket is in the position shown in the illustration.

        Tech Tips

        If not, turn the crankshaft damper sub-assembly 1 revolution (360°) to align the timing mark and sprocket as above.

    2. Check the valve clearance of the No. 1 cylinder exhaust valve and the No. 2 cylinder intake valve.

      A00478XE02

      1. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm sub-assembly.

        Text in Illustration
        *1 Camshaft
        *a No. 1 Cylinder Exhaust
        *b No. 2 Cylinder Intake
        *c Feeler Gauge
        *d View A
        *e Correct
        *f Incorrect
        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm sub-assembly.


        • Do not apply excessive force to the valve adjusting screw when using adjusting tools such as SST and a screwdriver.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    3. Check the valve clearance of the No. 1 cylinder intake valve and No. 3 cylinder exhaust valve.


      1. Turn the crankshaft damper sub-assembly by a further 180° clockwise.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm sub-assembly as shown in the illustration.

        A0048QJE02
        Text in Illustration
        *1 Camshaft
        *a No. 1 Cylinder Intake
        *b No. 3 Cylinder Exhaust
        *c Feeler Gauge
        *d View A
        *e Correct
        *f Incorrect
        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm sub-assembly.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    4. Check the valve clearances of the No. 3 cylinder intake valve and No. 4 cylinder exhaust valve.


      1. Turn the crankshaft damper sub-assembly clockwise by a further 180°.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm sub-assembly as shown in the illustration.

        A0046ZVE02
        Text in Illustration
        *1 Camshaft
        *a No. 3 Cylinder Intake
        *b No. 4 Cylinder Exhaust
        *c Feeler Gauge
        *d View A
        *e Correct
        *f Incorrect
        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm sub-assembly.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

    5. Check the valve clearances of the No. 2 cylinder intake valve and No. 4 cylinder intake valve.


      1. Turn the crankshaft damper sub-assembly clockwise by a further 180°.

      2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm sub-assembly.

        A004A9LE02
        Text in Illustration
        *1 Camshaft
        *a No. 2 Cylinder Exhaust
        *b No. 4 Cylinder Intake
        *c Feeler Gauge
        *d View A
        *e Correct
        *f Incorrect
        Valve clearance (cold)
        0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
        0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

        Note


        • Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm sub-assembly.

        • Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

        Tech Tips

        If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.

  18. ADJUST VALVE CLEARANCE

    A0047A3E08
    Text in Illustration
    *1 Valve Adjusting Screw
    *2 Valve Adjusting Nut

    1. Using SST and a screwdriver, loosen the valve adjusting nut while keeping the valve adjusting screw in position.

      SST
      09248-56010

    2. Adjust valve clearance (intake side).


      1. A0049J9E10
        Text in Illustration
        *1 Valve Adjusting Screw
        *2 Valve Adjusting Nut
        *a Feeler Gauge

        Insert a feeler gauge (0.14 mm (0.006 in.)) between the camshaft and No. 1 valve rocker arm sub-assembly, and turn the valve adjusting screw to adjust it.

        Valve clearance (cold)
        0.14 mm (0.006 in.)
      2. A004BEYE02
        Text in Illustration
        *1 Valve Adjusting Screw
        *2 Valve Adjusting Nut
        *a Fulcrum Length of SST
        *b Fulcrum Length of Torque Wrench

        Using SST and a screwdriver, tighten the valve adjusting nut while keeping the valve adjusting screw in position.

        Torque:
        Specified tightening torque
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 300 mm (11.81 in.)): 13 N*m (133 kgf*cm, 10 ft.*lbf).

    3. Adjust the valve clearance (exhaust side).

      Valve clearance (cold)
      0.17 mm (0.007 in.)

      Tech Tips

      Perform the same procedure as for the intake valve clearance adjustment.

  19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  20. INSTALL WIRING HARNESS CLAMP BRACKET (for LHD)


    1. Install the 2 wiring harness clamp brackets to the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    2. Connect the vacuum hose to the wiring harness clamp bracket.

  21. INSTALL WIRING HARNESS CLAMP BRACKET (for RHD)


    1. Install the wiring harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    2. Connect the vacuum hose to the wiring harness clamp bracket.

  22. CONNECT ENGINE WIRE (for LHD)


    1. Engage the 2 clamps and connect the engine wire.

    2. Connect the wiring harness clamp bracket to the cylinder head cover sub-assembly.

    3. Connect the 6 connectors.

  23. CONNECT ENGINE WIRE (for RHD)


    1. Engage the clamp and connect the engine wire.

    2. Connect the wiring harness clamp bracket to the cylinder head cover sub-assembly.

    3. Connect the 6 connectors.

  24. INSTALL SENSOR BRACKET

    Click here

  25. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  26. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  27. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  28. INSTALL NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  29. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

    Click here

  30. CONNECT NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Engage the clamp to connect the nozzle leakage pipe assembly to the hose clamp.

    2. Connect the nozzle leakage pipe assembly to the No. 2 nozzle leakage pipe and slide the hose clip to secure it.

  31. INSTALL NO. 1 FUEL HOSE SUB-ASSEMBLY


    1. Connect the No. 1 fuel hose sub-assembly to the No. 2 nozzle leakage pipe and slide the hose clip to secure it.

  32. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    Click here

  33. INSTALL VACUUM PUMP ASSEMBLY

    Click here