VALVE CLEARANCE ADJUSTMENT


  1. REMOVE INJECTOR ASSEMBLY

    Tech Tips

    Click here

  2. CHECK VALVE CLEARANCE


    1. A01CJ11E01

      Set the No. 1 cylinder to TDC/compression.

      Tech Tips

      Make sure that there is free play in the No. 1 cylinder rocker arms and that there is no free play in the No. 4 cylinder rocker arms.

    2. A01CGRRE01

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

      Valve clearance (Cold)
      Intake
      0.30 mm (0.0118 in.)
      Exhaust
      0.45 mm (0.0177 in.)

      Note

      Do not apply excessive force to the valve adjusting screw.

      Tech Tips

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

    3. A01CJ4ZE01

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

      Valve clearance (Cold)
      Intake
      0.30 mm (0.0118 in.)
      Exhaust
      0.45 mm (0.0177 in.)

      Note

      Do not apply excessive force to the valve adjusting screw.

      Tech Tips

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

    4. Turn the crankshaft by a further 360° clockwise.

    5. A01CJ11E01

      Set the No. 4 cylinder to TDC/compression.

      Tech Tips

      Make sure that there is free play in the No. 4 cylinder rocker arms and that there is no free play in the No. 1 cylinder rocker arms.

    6. A01CGOFE02

      Check the valve clearance of the No. 2 cylinder exhaust valve and the No. 4 cylinder intake valve.

      Valve clearance (Cold)
      Intake
      0.30 mm (0.0118 in.)
      Exhaust
      0.45 mm (0.0177 in.)

      Note

      Do not apply excessive force to the valve adjusting screw.

      Tech Tips

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

    7. A01CGMTE02

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

      Valve clearance (Cold)
      Intake
      0.30 mm (0.0118 in.)
      Exhaust
      0.45 mm (0.0177 in.)

      Note

      Do not apply excessive force to the valve adjusting screw.

      Tech Tips

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

  3. ADJUST VALVE CLEARANCE

    A01CH8ZE01

    1. Turn the crankshaft clockwise to align the matchmark on the crankshaft pulley with the pointer on the timing gear case.

      Tech Tips

      If not, turn the crankshaft 1 revolution (360°) to align the matchmark.

    2. A01CHWVE01

      With each piston positioned at TDC on the compression stroke, using a feeler gauge, adjust each valve clearance.

      Valve clearance (Cold)
      Intake
      0.30 mm (0.0118 in.)
      Exhaust
      0.45 mm (0.0177 in.)

      Tech Tips

      The feeler gauge should move with a very slight pull.

    3. Loosen the lock nut on the valve rocker arm and loosen the adjusting screw.

    4. Insert a 0.30 mm (0.012 in.) feeler gauge for the intake valve or a 0.45 mm (0.018 in.) feeler gauge for the exhaust valve between the adjusting screw on the valve rocker arm and the valve bridge.

    5. Turn the adjusting screw on the valve rocker arm until the feeler gauge slides with a very slight drag, and lock the adjusting screw with the lock nut.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  4. INSTALL INJECTOR ASSEMBLY

    Tech Tips

    Click here

  5. BLEED AIR FROM FUEL SYSTEM


    1. A01CGS9

      Loosen the fuel filter's air bleed plug.

      Note


      • Do not use any tools.

      • Do not allow any fuel to spill.

      • If any fuel spills on any part of the engine, wipe it clean with a shop rag or a piece of cloth.

    2. A01CGKM

      While covering the drain pipe with a shop rag or a piece of cloth, press and release the priming pump until the fuel from the drain pipe does not have any bubbles.

    3. A01CIWK

      Tighten the air bleed plug.

      Note

      Do not use any tools.

  6. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Select the following menu items: Powertrain / Engine / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Fuel leaks (common rail internal fuel pressure is raised) Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.