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          GI-RM-0002 - Valve clearance adjustment
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Instructions
Powertrain / Engine / Power Unit Service Procedures / GI-RM-0002 - Valve clearance adjustment
Measure valve clearances
 
Care Point:
The camshaft must be in the correct position to measure the valve clearances.
Care Point:
Remove the spark plugs to help you turn the crankshaft.
Care Point:
Make sure that unwanted objects do not enter the cylinders.
Care Point:
Make sure that unwanted objects do not enter the oil galleries.
Care Point:
Look at the camshaft lobes from the front of the engine to set the correct position.
Care Point:
Turn the crankshaft in a clockwise direction to position the camshaft correctly.
Care Point:
A left side cylinder head is shown. The right side cylinder head is symmetrically opposite.
 
1.  
The camshaft lobe must be at the 11 o'clock position (1) to measure inlet valve clearances.
 
2.  
The camshaft lobe must be at the 1 o'clock position (2) to measure exhaust valve clearances.
 
 
Care Point:
Make sure that the camshaft lobe is in the correct position.
 
3.  
Use feeler gauges to measure the clearance between the rocker (3) and the camshaft lobe (4).
 
4.  
Record the clearance that you have measured.
 
 
Care Point:
A clearance of 0.170mm to 0.200mm is permitted for the exhaust valves.
Care Point:
A clearance of 0.120mm to 0.150mm is permitted for the inlet valves.
 
5.  
Compare the value that you have recorded to the specified clearance tolerance.
 
6.  
Repeat steps 1 to 5 for each valve.
 
7.  
If any clearance is incorrect, the valve shim must be replaced with the correct size shim.
 
Replace valve shims
1.   
Do the steps that follow for any incorrect valve clearances.
 

2.   
Install the mount rail of the Valve spring compression tool kit (1) to the cylinder head.
 
3.   
Tighten the bolts (2) (M6x40) 10 Nm.
 
4.   
Tighten the bolts (3) 7 Nm.
 
 
Care Point:
Install the main body to the applicable pair of valves.
 
5.   
Install the main body of the Valve spring compression tool kit (4) to the mount rail (5).
 
6.   
Tighten the bolt (6) 15 Nm.
 
 
Care Point:
Make sure that unwanted objects do not go into the oil galleries.
 
7.   
Install plugs to make sure that unwanted objects do not go into the oil galleries (7).
 
 
Care Point:
Make sure the plunger is seated correctly on the valve cap.
Care Point:
Only compress the valve spring sufficiently to remove the valve shim. The valve can touch the piston.
 
8.   
Turn the bolt (8) clockwise to compress the valve spring.
 
9.   
Remove the valve shim (9).
 
10.  
Use a micrometer to measure the thickness of the valve shim that you have removed (10).
 
 
Care Point:
A clearance of 0.170 to 0.200 is permitted for the exhaust valves.
Care Point:
A clearance of 0.120 to 0.150 is permitted for the inlet valves.
Care Point:
Use the clearances that you recorded earlier.
 
11.  
Calculate the thickness of the shim that is necessary to get the correct clearance.
 
 
Care Point:
Visually examine the collets to make sure they are installed correctly.
 
12.  
Insert the correct shim.
 
13.  
Turn the bolt (11) counterclockwise to decompress the valve spring.
 
14.  
Do the procedure for each valve clearance that is not in tolerance.
 
15.  
Remove the main body (12) from the mount rail (13).
 
16.  
Turn the crankshaft clockwise through three complete turns.
 
 
Care Point:
Make sure that the camshafts are in the positions specified in steps 1 and 2 when you measure valve clearances.
 
17.  
Measure the valve clearances again.
 
 
Care Point:
All valve clearances must be in the specified range.
 
18.  
If any valve clearances are incorrect, you must go back to step 1 and install the necessary valve shims.
 
 
Care Point:
Only do this step after you have confirmed that each valve clearance is in the specified range.
 
19.  
Remove the main body from the mount rail.
 
20.  
Remove the mount rail from the cylinder head.
 
   
   
   Note