Valve Clearance Adjustment

Remove the intake camshaft as follows:

· Turn the crankshaft until the hole in the auxiliary gear is at the top. In this position, intake cams No. 1 and No. 3 press the tappet buckets down by the same amount at the same time.

· Remove the two bolts and No. 1 bearing cap.

· Loosen the bearing cap bolts alternately and remove bearing caps No. 1, 2 and 4. Do not fully remove the bolts of cap No. 3; leave them threaded in a few turns.

· Then fully remove the bolts of cap No. 3, remove the cap and lift out the camshaft, taking care not to damage the cylinder head.

· Remove the valve adjusting shims whose clearance deviates from the specification.

· Measure the thickness of the shim being removed with a micrometer. · Determine the thickness of the new shim required to obtain the specified valve clearance using the following formula: N = T + (A - 0.20 mm), where:

T - thickness of the shim removed; A - measured valve clearance; N - thickness of the new shim.

· Place the new shim on the valve lifter.

· Install the camshaft after replacing all shims as follows: turn the crankshaft pulley until the locating pin on the exhaust camshaft timing pulley is above the cylinder head edge. · Apply multi-purpose grease to all axial contact surfaces of the intake camshaft.

· Align the timing marks on the intake and exhaust camshaft gears with each other and allow the gears to mesh.

In this position, intake cams No. 1 and No. 3 press the tappet buckets down by the same amount at the same time.

· Install the four bearing caps in their original positions. The arrows must point toward the gears. Apply sealant to the contact surface of the right camshaft bearing cap and the cylinder head.

· Apply a small amount of engine oil to the threads and under the heads of the bearing cap bolts. Install the bolts and tighten them evenly in the specified sequence to the specified torque (Table 2.2.1).

· Remove the stud from the auxiliary gear and install the No. 1 bearing cap so that the arrow points forward toward the gear.

· If the bearing cap does not seat properly, push the auxiliary gear back with a screwdriver between the gear and the cylinder head. Apply a small amount of engine oil to the threads and under the bolt heads, then tighten the bolts alternately and evenly.

· Check the valve clearance of the exhaust valves again as follows:

· Turn the crankshaft until the cam on the camshaft of the valve being adjusted faces up.

· Turn the slot in the tappet bucket toward the front of the vehicle.

· Using valve adjusting tool SST09248-55020(A), press the tappet down and insert the auxiliary tool part (B) from the intake side (for rear valve No. 3, from the exhaust side) at a slight angle between the tappet and the camshaft.

Remove the adjusting shims (spacers) using special valve adjusting tool SST09248-55020(A) and the supplied auxiliary part (B). · Remove the adjusting shim with a small screwdriver and a magnet. · Determine the thickness of the adjusting shim required to obtain the specified valve clearance using the following formula: N = T + (A - 0.20 mm), where: T - thickness of the shim removed; A - measured valve clearance; N - thickness of the new shim. · Place the new shim on the valve lifter.

· Press the valve tappet down and remove auxiliary part (B).

· Check the valve clearance again.

· Remove all old gasket residue and apply silicone sealant to the cylinder head. · Place the gasket on the cylinder head cover and install the cover with the sealing washers and nuts on the cylinder head.

· Connect the crankcase ventilation hose and the spark plug leads. · Place the wiring harness and protective cover on the cylinder head cover, connect the alternator wiring and reconnect the negative battery terminal.