VALVE CLEARANCE(w/ Glow Plug Controller) ADJUSTMENT

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. REMOVE FRONT WHEEL RH

  3. REMOVE NO. 1 ENGINE UNDER COVER (for Half Cover Type)

    Click here

  4. REMOVE NO. 1 ENGINE UNDER COVER (for Full Cover Type)

    Click here

  5. REMOVE REAR ENGINE UNDER COVER RH

    Click here

  6. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    Click here

  7. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  9. DISCONNECT NO. 1 FUEL HOSE SUB-ASSEMBLY


    1. A01TALM

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

  10. DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01TB15

      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.

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

    Click here

  12. REMOVE NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  13. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  14. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  15. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  16. REMOVE SENSOR BRACKET

    Click here

  17. SEPARATE ENGINE WIRE (for LHD)

    A01TAQI

    1. Disconnect the 6 connectors shown in the illustration.

    2. Separate the harness bracket from the stud bolt.

    3. Disengage the 2 clamps and separate the engine wire.

  18. SEPARATE ENGINE WIRE (for RHD)


    1. A01T9M3

      Disconnect the 6 connectors shown in the illustration.

    2. Separate the harness bracket from the stud bolt.

    3. Disengage the clamp and separate the engine wire.

  19. REMOVE HARNESS BRACKET (for LHD)


    1. A01TBDI

      Disconnect the vacuum hose from the harness bracket.

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

  20. REMOVE HARNESS BRACKET (for RHD)


    1. A01TBPS

      Disconnect the vacuum hose from the harness bracket.

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

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  22. CHECK VALVE CLEARANCE


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


      1. A01TA6BC02
        *a Timing Mark
        *b Timing Pointer
        *c Groove

        Turn the crankshaft damper sub-assembly until the groove of the crankshaft damper sub-assembly and TDC mark of the timing chain cover sub-assembly are aligned.

      2. 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 of the camshaft timing sprocket as above.

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


      1. A01TD0XC05
        *1 Camshaft
        *2 No. 1 Valve Rocker Arm Sub-assembly
        *a View (A)
        *b No. 1 Cylinder Exhaust Valve
        *c No. 2 Cylinder Intake Valve
        *d Feeler Gauge
        *e Correct
        *f Incorrect

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

        Standard Valve Clearance (cold)
        Intake
        0.11 to 0.17 mm (0.00433 to 0.00669 in.)
        Exhaust
        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note


        • Center the feeler gauge with the roller and insert it 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 measurements, 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. A01TCDVC05
        *1 Camshaft
        *2 No. 1 Valve Rocker Arm Sub-assembly
        *a View (A)
        *b No. 1 Cylinder Intake Valve
        *c No. 3 Cylinder Exhaust Valve
        *d Feeler Gauge
        *e Correct
        *f Incorrect

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

        Standard Valve Clearance (cold)
        Intake
        0.11 to 0.17 mm (0.00433 to 0.00669 in.)
        Exhaust
        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note


        • Center the feeler gauge with the roller and insert it 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 measurements, and then adjust the valve clearance.

    4. Check the valve clearance 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. A01TB0LC05
        *1 Camshaft
        *2 No. 1 Valve Rocker Arm Sub-assembly
        *a View (A)
        *b No. 3 Cylinder Intake Valve
        *c No. 4 Cylinder Exhaust Valve
        *d Feeler Gauge
        *e Correct
        *f Incorrect

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

        Standard Valve Clearance (cold)
        Intake
        0.11 to 0.17 mm (0.00433 to 0.00669 in.)
        Exhaust
        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note


        • Center the feeler gauge with the roller and insert it 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 measurements, and then adjust the valve clearance.

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


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

      2. A01TB0JC05
        *1 Camshaft
        *2 No. 1 Valve Rocker Arm Sub-assembly
        *a View (A)
        *b No. 2 Cylinder Exhaust Valve
        *c No. 4 Cylinder Intake Valve
        *d Feeler Gauge
        *e Correct
        *f Incorrect

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

        Standard Valve Clearance (cold)
        Intake
        0.11 to 0.17 mm (0.00433 to 0.00669 in.)
        Exhaust
        0.14 to 0.20 mm (0.00551 to 0.00787 in.)

        Note


        • Center the feeler gauge with the roller and insert it 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 measurements, and then adjust the valve clearance.

  23. ADJUST VALVE CLEARANCE


    1. A01TD2MC01
      *1 Valve Adjusting Screw
      *2 Valve Adjusting Nut

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

      SST
      09248-56010
    2. A01TDN7C02
      *1 Valve Adjusting Screw
      *2 Valve Adjusting Nut
      *a Feeler Gauge

      Adjust valve clearance (intake side).


      1. Insert a feeler gauge (0.14 mm (0.00551 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 (0.00551 in.)
      2. A01TCQPC01
        *1 Valve Adjusting Screw
        *2 Valve Adjusting Nut
        *a Fulcrum Length of Torque Wrench

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

        SST
        09248-56010
        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.)): 13.3 N*m (136 kgf*cm, 10 ft.*lbf).

    3. Adjust the valve clearance (exhaust side).

      Valve Clearance (cold)
      0.17 mm (0.00669 in.)

      Tech Tips

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

  24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  25. INSTALL HARNESS BRACKET (for LHD)


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

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Connect the vacuum hose to the harness bracket.

  26. INSTALL HARNESS BRACKET (for RHD)


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

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Connect the vacuum hose to the harness bracket.

  27. CONNECT ENGINE WIRE (for LHD)


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

    2. Connect the harness bracket to the stud bolt.

    3. Connect the 6 connectors.

  28. CONNECT ENGINE WIRE (for RHD)


    1. Engage the clamp to connect the engine wire.

    2. Connect the harness bracket to the stud bolt.

    3. Connect the 6 connectors.

  29. INSTALL SENSOR BRACKET

    Click here

  30. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  31. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  32. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  33. INSTALL NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  34. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

    Click here

  35. 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.

  36. CONNECT 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.

  37. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  38. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  39. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    Click here

  40. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  41. INSTALL NO. 1 ENGINE UNDER COVER (for Half Cover Type)

    Click here

  42. INSTALL NO. 1 ENGINE UNDER COVER (for Full Cover Type)

    Click here

  43. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }