Valve Clearance Check: Adjust
WARNING: This page is about a different variant/trim than selected.
- Undo the bolts in the upper timing belt cover.
- Remove the cylinder head cover.
- Pull off the spark plug connectors.
- Detach the crankcase ventilation hose.
- Unscrew the 10 bolts.
- Set the engine to TDC on cylinder number 1.
- Measure the valve clearance using feeler gauges.
- Permitted valve clearance: inlet (0.11-0.18 mm)
- Permitted valve clearance: exhaust (0.27-0.34 mm)
- Measure the valve clearance (continued).
- Rotate the engine a further 180 degrees on the crankshaft in its rotation direction. In this instance, the measuring sequence follows the firing order 1-3-4-2.
- Repeat the previous steps for the other cylinders.
- Remove the camshafts. For additional information, refer to CAMSHAFTS .
- Determine the tappet thickness required.
- Remove the adjusting tappet and read the thickness from the back side.
- Determine the tappet thickness required and insert the correct tappet.
- Inlet valves: tappet thickness required = thickness of currently installed tappet + measured valve clearance - 0.15 mm.
- Exhaust valves: tappet thickness required = thickness of currently installed tappet + measured valve clearance - 0.30 mm.
- Install the camshafts and camshaft timing belts. For additional information, refer to CAMSHAFTS .
- Recheck the valve clearance after adjustment is complete.
- Install the timing belt. For additional information, refer to TIMING BELT .
- Install the cylinder head cover.
- Insert the 10 bolts and tighten them in two stages.
- Stage 1: 2 Nm.
- Stage 2: 7 Nm.
- Attach the crankcase ventilation hose.
- Fit the spark plug connectors and make sure that they engage correctly.
- Insert the 10 bolts and tighten them in two stages.
- Install the upper timing belt cover.
- Connect the battery ground cable.
- Check the fluid levels and adjust if necessary.
- Check that the vacuum hoses and cables are routed correctly and fix in place using cable ties.
CAUTION:
Exchange the tappets to correct the valve clearance.
CAUTION:
Disconnect the battery ground cable.
NOTE:
Do not remove the upper timing belt cover.
CAUTION:
Do not pull the spark plug connectors by the ignition wires when removing them. If necessary pull off the ignition wires from the ignition coils to prevent kinking the ignition wires. Slightly twist the spark plug connectors before removing them in order to loosen the seals.
CAUTION:
Pull off the spark plug connectors in line with the spark plugs.
NOTE:
Loosening sequence: from the outside to the inside, working diagonally.
CAUTION:
Only rotate the engine on the crankshaft and in its rotation direction.
NOTE:
Note down each cylinder number and the valve clearances measured.
CAUTION:
Only rotate the engine on the crankshaft.
NOTE:
Only carry out the following steps when the valve clearance must be adjusted.
NOTE:
Aim to set the valve clearances to the middle of the range (inlet 0.15 mm; exhaust 0.30 mm)
NOTE:
The number on the tappet indicates the tappet thickness.
CAUTION:
Set the piston on cylinder number 1 to approximately 25 mm before TDC.
NOTE:
Turn the camshaft to measure the valve clearance.
CAUTION:
Use a blunt object (a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors.
CAUTION:
Push on the spark plug connectors, keeping them in line with the spark plugs.
NOTE:
Apply silicone grease to the inside of the spark plug connectors to a depth of 5-10 mm.
NOTE:
Check that the gasket on the upper timing belt cover is seated correctly and adjust if necessary.
NOTE:
When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.