GSIC - Global Service Information Center

# VALVE CLEARANCE > ADJUSTMENT

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

  Wait for least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

1. Remove the 3 bolts, 2 nuts and cover.

3. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

1. Disconnect the diesel turbo IAT sensor connector.

1. Loosen the 2 hose clamps of the No. 1 air hose.

1. Loosen the 2 hose clamps of the No. 2 air hose.

1. Remove the 4 bolts and CAC.

1. Using a 22 mm deep socket wrench, remove the IAT sensor.

   HINT:
     Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.

1. Remove the 4 bolts, intake air connector and gasket.

4. LOOSEN FUEL TANK CAP ASSEMBLY

5. REMOVE INJECTION PIPE

NOTICE:

1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

1. Remove the 2 nuts and No. 3 injection pipe clamp.

1. Remove the bolt and No. 2 injection pipe clamp.

1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

   SST
     09023-12701

   1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.

   2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
        09023-12701

6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

1. Using a small screwdriver, remove the holder seal by prying the portion between the holder seal and the cutout part of the cylinder head.

1. Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.

7. REMOVE INJECTOR ASSEMBLY

1. Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.

   NOTICE:
   1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   2. Be careful not to deform or scratch the union seal surface.
   3. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

1. Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

   HINT:
     Arrange the injectors, holder clamps, washers and bolts in the correct order.

1. Remove the O-ring and back-up ring from the injector.

1. Remove the 4 injection nozzle sheets from the cylinder head.

8. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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

   HINT:
     Make sure that both cam-noses (intake side and exhaust side) of the No. 1 cylinder face upward.

9. INSPECT VALVE CLEARANCE

1. Check only the valves indicated.

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

      Valve clearance (Cold):

        Intake | Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) | 0.35 to 0.45 mm (0.014 to 0.018 in.)

      Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

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

1. Check only the valves indicated.

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

      Valve clearance:

        Intake | Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) | 0.35 to 0.45 mm (0.014 to 0.018 in.)

      Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

10. ADJUST VALVE CLEARANCE

1. Drain coolant.

1. Remove the fan shroud.

1. Remove the No. 1 timing belt cover.

1. Remove the timing belt.

1. Remove the camshaft timing pulley.

1. Remove the No. 1 timing belt idler.

1. Remove the No. 2 timing belt cover.

1. Remove the camshafts.

1. Remove the valve lifters.

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

1. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

   Valve clearance:

     A | B | C
     Thickness of new lifter | Thickness of used lifter | Measured valve clearance

   Valve clearance (Cold):
     Intake A = B + (C - 0.25 mm (0.0098 in.))

   Valve clearance (Cold):
     Exhaust A = B + (C - 0.40 mm (0.00158 in.))

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

   HINT:
     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.).

1. Install the selected valve lifter.

   Intake valve clearance (Cold):
     0.20 to 0.30 mm (0.008 to 0.012 in.)

   EXAMPLE:
     The 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.) shim with a No. 40 lifter.

   New Lifter Thickness mm (in.):

     Shim No. | Thickness | Shim No. | Thickness | Shim No. | Thickness
     06 | 5.060 (0.1992) | 30 | 5.300 (0.2087) | 54 | 5.540 (0.2181)
     08 | 5.080 (0.2000) | 32 | 5.320 (0.2094) | 56 | 5.560 (0.2189)
     10 | 5.100 (0.2008) | 34 | 5.340 (0.2102) | 58 | 5.580 (0.2197)
     12 | 5.120 (0.2016) | 36 | 5.360 (0.2110) | 60 | 5.600 (0.2205)
     14 | 5.140 (0.2024) | 38 | 5.380 (0.2118) | 62 | 5.620 (0.2213)
     16 | 5.160 (0.2031) | 40 | 5.400 (0.2126) | 64 | 5.640 (0.2220)
     18 | 5.180 (0.2039) | 42 | 5.420 (0.2134) | 66 | 5.660 (0.2228)
     20 | 5.200 (0.2047) | 44 | 5.440 (0.2142) | 68 | 5.680 (0.2236)
     22 | 5.220 (0.2055) | 46 | 5.460 (0.2150) | 70 | 5.700 (0.2244)
     24 | 5.240 (0.2063) | 48 | 5.480 (0.2157) | 72 | 5.720 (0.2252)
     26 | 5.260 (0.2071) | 50 | 5.500 (0.2165) | 74 | 5.740 (0.2260)
     28 | 5.280 (0.2079) | 52 | 5.520 (0.2173) | - | -

   Exhaust valve clearance (Cold):
     0.35 to 0.45 mm (0.014 to 0.018 in.)

   EXAMPLE:
     The 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.) shim with a No. 42 lifter.

   New Lifter Thickness mm (in.):

     Shim No. | Thickness | Shim No. | Thickness | Shim No. | Thickness
     06 | 5.060 (0.1992) | 30 | 5.300 (0.2087) | 54 | 5.540 (0.2181)
     08 | 5.080 (0.2000) | 32 | 5.320 (0.2094) | 56 | 5.560 (0.2189)
     10 | 5.100 (0.2008) | 34 | 5.340 (0.2102) | 58 | 5.580 (0.2197)
     12 | 5.120 (0.2016) | 36 | 5.360 (0.2110) | 60 | 5.600 (0.2205)
     14 | 5.140 (0.2024) | 38 | 5.380 (0.2118) | 62 | 5.620 (0.2213)
     16 | 5.160 (0.2031) | 40 | 5.400 (0.2126) | 64 | 5.640 (0.2220)
     18 | 5.180 (0.2039) | 42 | 5.420 (0.2134) | 66 | 5.660 (0.2228)
     20 | 5.200 (0.2047) | 44 | 5.440 (0.2142) | 68 | 5.680 (0.2236)
     22 | 5.220 (0.2055) | 46 | 5.460 (0.2150) | 70 | 5.700 (0.2244)
     24 | 5.240 (0.2063) | 48 | 5.480 (0.2157) | 72 | 5.720 (0.2252)
     26 | 5.260 (0.2071) | 50 | 5.500 (0.2165) | 74 | 5.740 (0.2260)
     28 | 5.280 (0.2079) | 52 | 5.520 (0.2173) | - | -

1. Install the camshaft.

1. Install the No. 2 timing belt cover.

1. Install the No. 1 timing belt idler.

1. Install the camshaft timing pulley.

1. Install the timing belt.

1. Install the No. 1 timing belt cover.

1. Install the fan shroud.

1. Add engine coolant.

11. INSTALL INJECTOR ASSEMBLY

NOTICE:

  Be sure to install the injector, holder clamp, washer and bolt in their original positions.

1. Install 4 new injection nozzle sheets to the cylinder head.

1. Apply a light amount of clean engine oil to 4 new O-rings.

1. Install the O-ring to each injector as shown in the illustration.

1. Insert the 4 injectors into the cylinder head.

   NOTICE:
   1. At this time, insert the injector until it touches the nozzle sheet surface.
   2. After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
   3. Always return an injector to the same place it was removed from.

1. Register injector compensation code (when replacing with a new injector).

1. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

   HINT:
     Apply a light amount of engine oil to the threads and under the heads of the clamp bolts.

   NOTICE:
   2. The fork portion of the nozzle holder clamp must be set to the injector.
   3. Before tightening the bolts, check that the nozzle holder clamp is set properly.
   4. To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at following step.
   5. When tightening the bolts, pay attention not to tilt the bolt and the clamp.
   6. Do not reuse the washer.
   7. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

1. Temporarily install the 4 injection pipes with the union nuts.

   HINT:
     To position the injectors, loosely tighten the union nut.

1. Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.
   If scratches or dents are present, replace the nozzle leakage pipe.

1. Set the leakage pipe and 5 new gaskets in place.

1. Apply a light amount of oil to the 4 hollow screws and union bolt.

1. Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

1. Tighten the 4 holder clamp bolts.

   Torque:
     22 N*m{ 224 kgf*cm , 16 ft.*lbf }

1. Tighten the 4 hollow screws in order from 1 to 4.

   Torque:
     16 N*m{ 163 kgf*cm , 12 ft.*lbf }

   NOTICE:
     If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

1. Tighten the union bolt.

   Torque:
     12.5 N*m{ 127 kgf*cm , 9 ft.*lbf }

   NOTICE:
     If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

1. Remove the 4 injection pipes.

12. CHECK FOR FUEL LEAKS

1. Check that there are no leaks from the nozzle leakage pipe connection.

   1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

      Part No.:
        23762-27010 (No. 2 nozzle leakage pipe)
      SST
        09280-00010

      Torque:
        21 N*m{ 214 kgf*cm , 16 ft.*lbf }

   2. Apply a light amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

   3. Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 250 kPa (2.5 kgf/cm２, 35.5 psi) of pressure for 60 seconds to check that no bubbles form.

      SST
        09992-00242

      NOTICE:
        Before checking the leakage, be sure to remove the ball and spring in the check valve.

   4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

   5. Remove SST, No. 2 nozzle leakage pipe and gasket.

      SST
        09280-00010
        09992-00242

      HINT:
        Never reinstall the disassembled check valve on the engine.

13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

1. Remove any old seal packing (FIPG) material from the cylinder head.

1. Apply seal packing to the specific areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the belt cover within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 2 hours after installing the seal packing.

1. Install the gasket and cylinder head cover with the 10 bolts and 2 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install 4 new nozzle holder seals.

14. INSTALL INJECTION PIPE

NOTICE:

1. When replacing the injector, also replace the injection pipe.
2. Keep the joints of the injection pipe clean.

1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

   Torque:
     5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

   HINT:
     If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

1. Using SST, tighten the injection pipe union nuts on the common rail side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Using SST, tighten the injection pipe union nuts on the injector side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Temporarily install the No. 4 injection pipe with the union nuts.

1. Install 2 new injection pipe clamps with the 2 bolts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

   NOTICE:
   1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.

1. Using SST, tighten the injection pipe union nuts on the common rail side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Using SST, tighten the injection pipe union nuts on the injector side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

15. INSTALL CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

1. Install a new gasket and the intake air connector with the 4 bolts.

   Torque:
     10 N*m{ 102 kgf*cm , 7 ft.*lbf }

1. Using a 22 mm deep socket wrench, install a new gasket and the IAT sensor.

   Torque:
     29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }

1. Install the CAC with the 4 bolts.

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for bolt A

   Torque:
     12 N*m{ 122 kgf*cm , 9 ft.*lbf } for bolt B

1. Tighten the 4 hose clamps of the No. 1 and No. 2 air hose.

   Torque:
     6.5 N*m{ 66 kgf*cm , 58 in.*lbf }

1. Connect the diesel turbo IAT sensor connector.

16. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

1. Install the cover with the 3 bolts and 2 nuts.

   Torque:
     7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

17. ADD FUEL

18. TIGHTEN FUEL TANK CAP ASSEMBLY

19. BLEED AIR FROM FUEL SYSTEM

1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

21. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

22. CHECK FOR FUEL LEAKS

23. CHECK FOR ENGINE OIL LEAKS