Repair Procedures

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

1. 1
   Remove the cylinder head cover. (Refer to Cylinder Head - "Cylinder Head Cover")
2. 2
   Set the No. 1 cylinder to TDC/compression stroke.

   1. Turn the crankshaft pulley and align its groove with the "T" mark on the timing chain cover.

      

   2. Make sure the TDC marks on the intake CVVT sprocket and the exhaust camshaft sprockets are aligned in a straight line on the cylinder head surface, as shown in the illustration. If not, turn the crankshaft one full revolution (360°).

      

3. 3
   Inspect the valve clearance.

   1. Check only the specified valves (1st intake and 1st and 2nd exhaust). Measure the valve clearance.

      

      • Using a feeler gauge, measure the clearance between the tappet and the camshaft base circle.
      • Note the valve clearance measurements that are outside the specification. They will be used later to determine which adjusting shim to select for replacement.
      Valve Clearance [Engine Coolant Temperature: 20 °C] [Specification] INTAKE: 0.20~0.26 mm (0.0079~0.0102 in.) EXHAUST: 0.39~0.45 mm (0.0154~0.0177 in.)
   2. Rotate the intake and exhaust camshafts 210° clockwise.

      

   3. Check only the valves specified below (2nd and 3rd intake and 3rd exhaust). Measure the valve clearance.

      

4. 4
   Adjust the intake and exhaust valve clearance.

   1. Position No. 1 cylinder at TDC/compression.
   2. Remove the camshaft assembly. (Refer to Cylinder Head - "CVVT and Camshaft")
   3. Using a micrometer, measure the thickness of the removed tappet.

      

   4. Calculate the thickness of the new tappet so that the valve clearance is within the specified value. Valve Clearance [Engine Coolant Temperature: 20 °C] T: Thickness of removed tappet A: Measured valve clearance N: Thickness of new tappet Intake: N = T + [A - 0.2 mm (0.0079 in.)] Exhaust: N = T + [A - 0.25 mm (0.0098 in.)]
   5. Select a new tappet whose thickness is as close as possible to the calculated value.
   6. After applying engine oil to the outer surface and top surface of the selected tappet, carefully insert the tappet into the cylinder head bore.
   7. Install the intake camshaft and exhaust camshaft. (Refer to Cylinder Head - "CVVT and Camshaft")
   8. Turn the crankshaft two revolutions in the direction of operation (clockwise), then make sure the TDC marks on the intake and exhaust CVVT camshaft sprockets are aligned in a straight line on the cylinder head surface.

      

   9. Check the valve clearance again. Valve Clearance [Engine Coolant Temperature: 20 °C] [Specification] INTAKE: 0.20~0.26 mm (0.0079~0.0102 in.) EXHAUST: 0.39~0.45 mm (0.0154~0.0177 in.)