Valve Clearance Adjustment Procedure(4D5 Engine) Rev.

04

No Process Keypoint

1 Remove timing belt cover (upper part).

2 Remove cylinder head cover. *Be careful for oil seal damage.

Turn crankshaft clockwise to set all mark on camshaft and crankshaft sprocket to *Counter clockwise turning may cause damage
3
correct position. (No. 1 cylinder at TDC on compression stroke) to belt tensioner

*Standard:
4 Check and adjust valve clearance (Intake of cylinder no.1,2 > Exhaust of cylinder no. 1,3). Intake: 0.09 mm.
Exhaust: 0.14 mm.

5 Tighten valve adjust lock nut by torque wrench correctly. *Standard: 15±3 N.m.

6 Check valve clearance by filler gauge.

Turn cranshaft clockwist 1 round.(No. 4 cylinder at TDC on compression stroke or No.1 cylinder on overlap *Counter clockwise turning may cause damage
7
position) to belt tensioner

*Standard: Intake: 0.09 mm.

8 Check and adjust valve clearance (Intake of cylinder no. 3,4 > Exhaust of cylinder no. 2,4).
Exhaust: 0.14 mm.

9 Tighten valve adjust lock nut by torque wrench correctly. *Standard: 15±3 N.m.

10 Check valve clearance by filler gauge.

11 Assemble cylinder head cover. *Be careful for oil seal damage.

12 Assemble timing belt cover (upper part).

Prosedur penyetelan valve clearance pada engine stand

No Proses Keypoint

1 Lepas cover atas timming belt

2 Lepas Cylinder head cover *Hati hati , seal oli russak

Putar crancshaft searah jarum jam, pastikan marking pada cam dan crankshaft sproket berada pada posisi *putaran berlawanan jarum jam bisa
3
yang tepat ( cylinder no. 1 pada posisi TDC Compresi) menyebabkan kerusakan pada belt tensioner.

*Standard:
4 Periksa dan lakukan penyetelan valve clearance ( Intane no. 1,2 and exhaus no. 1,3 ) Intake: 0.09 mm.
Exhaust: 0.14 mm.

5 Kencangkan valve adjusting lock nut dengan torque wrench *Standard: 15±3 N.m.

6 Periksa valve clearance dengan filler gauge

*putaran berlawanan jarum jam bisa

7 Putar crankshaft 1 putaran searah jarum jam.(Cylinder no. 4 pada posisi TDC compresi)
menyebabkan kerusakan pada belt tensioner.

*Standard: Intake: 0.09 mm.

8 Periksa dan lakukan penyetelan valve clearance ( Intane no. 3,4 and exhaus no. 2,4 )
Exhaust: 0.14 mm.

9 Kencangkan valve adjusting lock nut dengan torque wrench *Standard: 15±3 N.m.

10 Periksa valve clearance dengan filler gauge

11 Pasang cylinder head cover *Hati hati , seal oli russak

12 Pasang cover timming belt

Valve Clearance Adjustment Procedure(4D5 Engine) Rev. 04

No Process Keypoint Instruction point

Leave 1 bolt on belt cover for:

1 Remove timing belt cover (upper part). - Check for Timing mark position
- Remove cylinder cover front bolts

2 Remove cylinder head cover. *Be careful for oil seal damage. No need if change oil seal*1

Turn crankshaft clockwise to set all mark on camshaft and

*Counter clockwise turning may cause damage Mark on crankshaft and camshaft spocket are
3 crankshaft sprocket to correct position.
to belt tensioner direct position
(No. 1 cylinder at TDC on compression stroke)

*Standard:
Check and adjust valve clearance (Intake of cylinder no.1,2 > Exhaust of
4 Intake: 0.09 mm.
cylinder no. 1,3).
Exhaust: 0.14 mm.

5 Tighten valve adjust lock nut by torque wrench correctly. *Standard: 15±3 N.m.

Check for valve clearance by filler

6 Check valve clearance by filler gauge. gauge 3 thickness , over size, correct size
and lower size*2

Turn cranshaft clockwist 1 round.(No. 4 cylinder at TDC on compression *Counter clockwise turning may cause damage
7 Check mark on crankshaft
stroke or No.1 cylinder on overlap position) to belt tensioner

Check and adjust valve clearance (Intake of cylinder no. 3,4 > Exhaust of *Standard: Intake: 0.09 mm.
8
cylinder no. 2,4). Exhaust: 0.14 mm.

9 Tighten valve adjust lock nut by torque wrench correctly. *Standard: 15±3 N.m.

10 Check valve clearance by filler gauge.

11 Assemble cylinder head cover. *Be careful for oil seal damage.

12 Assemble timing belt cover (upper part).

Remark: Rev1(from 22 Sep, 2013), *1: Rev 2 (from 25 Nov, 2013), *2: Rev3 (from 5 Jan, 2014), *3 Rev4 (from 29 April, 2014)
Prosedur penyetelan valve clearance pada engine stand Rev. 04

No Proses Keypoint Instruksi poin

sisakan 1 baut cover timming belt untuk

1 Remove timing belt cover (upper part). memeriksa timming mark position dan melepas
baut cylinder cover front

2 Remove cylinder head cover. *Be careful for oil seal damage. Tidak perlu dilakukan apabila seal oli diganti *1

Turn crankshaft clockwise to set all mark on camshaft and

*Counter clockwise turning may cause damage Tandai crankshaft dan camshaft sproket pada
3 crankshaft sprocket to correct position.
to belt tensioner direct posisi
(No. 1 cylinder at TDC on compression stroke)

*Standard:
Check and adjust valve clearance (Intake of cylinder no.1,2 > Exhaust of
4 Intake: 0.09 mm.
cylinder no. 1,3).
Exhaust: 0.14 mm.

5 Tighten valve adjust lock nut by torque wrench correctly. *Standard: 15±3 N.m.

Periksa valve clearance pada tiga posisi, over,

6 Check valve clearance by filler gauge.
correct, under size. *2

Turn cranshaft clockwist 1 round.(No. 4 cylinder at TDC on compression *Counter clockwise turning may cause damage
7 Periksa tanda pada crankshaft
stroke or No.1 cylinder on overlap position) to belt tensioner

Check and adjust valve clearance (Intake of cylinder no. 3,4 > Exhaust of *Standard: Intake: 0.09 mm.
8
cylinder no. 2,4). Exhaust: 0.14 mm.

9 Tighten valve adjust lock nut by torque wrench correctly. *Standard: 15±3 N.m.

10 Check valve clearance by filler gauge.

11 Assemble cylinder head cover. *Be careful for oil seal damage.

12 Assemble timing belt cover (upper part).

Remark: Rev1(from 22 Sep, 2013), *1: Rev 2 (from 25 Nov, 2013), *2: Rev3 (from 5 Jan, 2014), *3 Rev4 (from 29 April, 2014)
 Score Sheet for Valve Clearance Adjustment Station

……….. Time Raw Time …………… Min Total Time ………. Min

Name - Surname ….…...………....………..…….Course ………............. Participant ID ……….....………….

Topic Score OK NG Remark

1.Remove cylinder head cover correctly. 5 Be careful for oil seal damage.

2. Turn crankshaft to set no.1 cylinder at Clockwise turn,

5 Mark is in right position
compression stroke correctly.
Should do not switch
3. Adjust valve clearance correctly. 10 working order
(All Intake > All exhaust)

4. Tighten valve adjust lock nut by torque wrench 10 Standard: 15±3 N.m.
correctly.
Standard:
5. Check valve clearance by filler gauge correctly. 10 Intake: 0.09±0.01 mm.
Exaust: 0.14±0.01 mm.

6. Turn crankshaft to set no.4 cylinder at

compression stroke correctly. 5 clockwise turn
(no. 1 cylinder at overlap position)
Should do not switch
7. Adjust valve clearance correctly. 10 working order
(All Intake > All exhaust)

8. Tighten valve adjust lock nut by torque wrench 10 Standard: 15±3 N.m.
correctly.
Standard:
9. Check valve clearance by filler gauge correctly. 10 Intake: 0.09±0.01 mm.
Exaust: 0.14±0.01 mm.

10. Assemble cylinder head cover correctly. 5 Be careful for oil seal damage.

11. Clean and College all tools. 5

12. Finish work within limited time. 5 Within 48 minutes

13. Work correctly and safely. 10

Total Score 100 Test Score

Note: Checked by:………………………………………….

 Lembar penilaian penyetelan valve clearance

Total Time ………. Min

Nama ......... ….…...………....………..…….Course ………............. No. Reg ……….....………….

Item penilaian Score OK Poin Keteragan

1.Lepas Cylinder head cover 5 Perhatikan seal oli

Putar searah jarum jam, dan

2. Putar crankshaft pada pusisi cylinder no. 1 pada
5 pastikan marking pada posisi
posisi top compresi tepat

sesuai dengan firiong order

3. Lakukan penyetelan valve clearance 10 (All Intake > All exhaust)

4. Kencangkan valve clearance adjusting lock nut 10 Standard: 15±3 N.m.

dengan torqque wrench
Standard:
5. Periksa valve clearance dengan filler gauge 10 Intake: 0.09±0.01 mm.
Exaust: 0.14±0.01 mm.

6. Putar crankshaft ke posisi cylinder no. 4 TDC

5 Searah jarum jam
compressi posisi (Cylinder no.1 pada posisi overlap)

sesuai dengan firiong order

7.Lakukan penyetelan valve clearance 10 (All Intake > All exhaust)

8. Kencangkan valve clearance adjusting lock nut 10 Standard: 15±3 N.m.

dengan torque wrench
Standard:
9. Periksa valve clearance dengan filler gauge 10 Intake: 0.09±0.01 mm.
Exaust: 0.14±0.01 mm.

10. Pasang cylinder head civer 5 Perhatikan seal oli

11. Bersihkandan rapihkan toos 5

12. Menyelesaikan pekerjaan tepat waktu 5 30 minutes

13. Lakukan pekerjaan dengan tepat dan aman 10

Total Score 100 Test Score

Note: Diperiksa Oleh :………………………………………