VALVE CLEARANCE ADJUSTMENT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.

Tech Tips

The injectors do not need to be removed when inspecting the valve clearance.


  1. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01E1R0E02

      Align the matchmarks of the crankshaft pulley and timing gear case cover by rotating the crankshaft clockwise.

      Tech Tips

      Make sure that both cam lobes (intake side and exhaust side) of the No. 1 cylinder face upward.

  3. INSPECT VALVE CLEARANCE

    A01DX9JE02

    1. Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard Valve Clearance (Cold)
        Item Specified Condition
        Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
        Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down any valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment lifter to be installed.

    2. Turn the crankshaft 360° to set the No. 4 cylinder to TDC/compression.

    3. A01E0RDE02

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard Valve Clearance
        Item Specified Condition
        Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
        Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down any valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment lifter to be installed.

  4. ADJUST VALVE CLEARANCE


    1. Remove the injector.

    2. Remove the timing belt.

    3. Remove the camshaft timing pulley.

    4. Remove the No. 2 timing belt cover.

    5. Remove the camshafts.

    6. Remove the valve lifters.

    7. A01DVS9E01

      Using a micrometer, measure the thickness of the removed lifter.

    8. Calculate the thickness of a new lifter so that the valve clearance is within the specified range.

      A B C
      New lifter thickness Used lifter thickness Measured valve clearance
      New lifter thickness
      Intake A = B + (C - 0.25 mm (0.0098 in.))
      Exhaust A = B + (C - 0.40 mm (0.00158 in.))

    9. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips

      Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

      A01DWV3E01
      A01DZ1SE01
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a No. 40 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
      A01DUZHE01
      A01DYK2E01
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) lifter with a No. 42 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -

    10. Install the selected valve lifter.

    11. Install the camshaft.

    12. Install the No. 2 timing belt cover.

    13. Install the camshaft timing pulley.

    14. Install the timing belt.

    15. Install the fuel injector.

  5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


  6. INSPECT FOR COOLANT LEAK

    Check for engine coolant leaks Click here.

  7. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01DYT1E05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  8. INSPECT FOR FUEL LEAK

    A01E2P1E01

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

    2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

    3. Disconnect the return hose from the common rail.

    4. Start the engine and check for fuel leaks from the return pipe.

      If there is fuel leakage, replace the common rail.

    5. Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

    8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

      If there is fuel leakage, repair or replace parts as necessary.

    10. Reconnect the return hose to the common rail.

  9. INSPECT FOR OIL LEAK

  10. INSPECT ENGINE OIL LEVEL