Page 1689 of 2267

IUsing a feeler gauge, measure clearance between valve lifter
and camshaft.
IRecord any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance for checking (Hot):
Intake
0.25 - 0.35 mm (0.010 - 0.014 in)
Exhaust
0.39 - 0.49 mm (0.015 - 0.019 in)
3. Turn crankshaft one revolution (360É) until No. 4 cylinder is at
TDC on its compression stroke.
4. Check valve clearances of valve lifter No.
p3,p5,p7and
p8.
IUse the same procedure as mentioned in step 3.
5. If all valve clearances are within specification, install the fol-
lowing parts:
IRocker cover
Adjusting
Adjust valve clearance while engine is cold.
1. Turn crankshaft. Position cam lobe upward on camshaft for
valve that must be adjusted.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A), rotate notch toward center of cylinder
head. (See figure.) This will simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
4. Place Tool (B) between camshaft and valve lifter to retain valve
lifter.
CAUTION:
ITool (B) must be placed as close to camshaft bracket as
possible.
IBe careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
SEM634F Feeler gauge
SMA406A
.SEM636F Face directly upwards.
Notch
.SEM637F Tool (B)
KV10115120
Tool (A)
KV10115110
CYLINDER HEADCD20T
Checking (Cont'd)
EM-149
Page 1690 of 2267

6. Remove adjusting shim using a small screwdriver and a mag-
netic finger.
7. Determine replacement adjusting shim size using the following
formula.
IUse a micrometer to determine thickness of removed shim.
ICalculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
S = Standard valve clearance (neutral value for calculation)
Unit: mm (in)
HOTIntake 0.30 (0.012)
Exhaust 0.44 (0.017)
COLDIntake 0.25 (0.010)
Exhaust 0.38 (0.015)
Intake:
N=R+[MþS]
Exhaust:
N=R+[MþS]
Shims are available in 15 sizes from 2.20 mm (0.0866 in) to 2.90
mm (0.1142 in), in steps of 0.05 mm (0.0020 in).
ISelect the closest size shim to the calculated thickness.
Refer to chart in SDS, EM-198.
8. Install new shim using a suitable tool.
IInstall with the surface on which the thickness is stamped
facing down.
9. Place Tool (A) as explained in steps 2 and 3.
10. Remove Tool (B).
11. Remove Tool (A).
12. Recheck valve clearance.
Valve clearance:
Unit: mm (in)
For adjusting
Hot Cold* (reference data)
Intake0.25 - 0.35
(0.010 - 0.014)0.20 - 0.30
(0.008 - 0.012)
Exhaust0.39 - 0.49
(0.015 - 0.019)0.33 - 0.43
(0.013 - 0.017)
*: At a temperature of approximately 20ÉC (68ÉF)
Whenever valve clearances are adjusted to cold specifications, check that the
clearances satisfy hot specifications and adjust again if necessary.
SEM638F Small screwdriver
Magnetic finger
SEM145D
AEM236 Indicate
T
1= 2.800 mm
(0.1102 in)
Shim
CYLINDER HEADCD20T
Adjusting (Cont'd)
EM-150
Page 1691 of 2267

Assembly
1. Install valve component parts.
Install valve spring with its narrow pitch side toward cylinder
head side.
IAlways install new valve oil seals.
Refer to oil seal replacement.
IBefore installing oil seal, install valve-spring seat.
IWhen installing valve, apply engine oil on the valve stem
and lip of valve oil seal.
ICheck whether the valve face is free from foreign matter.
IInstall valve spring retainers on the intake side and valve
rotators on the exhaust side.
IValve rotators cannot be disassembled.
IInstall valve shims
IAdjust valve clearance
2. Install camshaft and brackets and tighten bracket nuts to the
specified torque in two or three stages.
Camshaft-bracket nuts:
: 18 - 22 N´m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
ITighten bracket from center to outside.
IApply sealant to brackets No. 1 and No. 5.
IWhen installing brackets, set camshaft so that the pin of
camshaft front head is uppermost.
IInstall new camshaft oil seals.
Refer to oil seal replacement.
Installation
1. Install cylinder head gasket.
IWhen replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
IWhen replacing or repairing cylinder block, piston, con-
necting rod and crankshaft, select gasket referring to
ªSelecting cylinder head gasketº.
IPay attention to the direction of the cylinder head bolt
washer as shown in the figure.
2. Install cylinder head and tighten cylinder head bolts according
to the following sequence.
SEM202 Painted side
Cylinder
head side
Narrow
pitchWide pitch
SEM731BA
SEM528D Grade number
Tightening sequence
Facing front of engine
(position 2)
SEM676D 17.5 (0.689)
13.0 (0.512)
No. 1 journal bracket No. 5 journal bracket
Unit: mm (in)
SEM675D Cylinder headCylinder head bolt
Washer
CYLINDER HEADCD20T
Assembly
EM-151
Page 1692 of 2267
CAUTION:
The cylinder head bolts can be reused providing dimension
ªAº is not exceeded.
Dimension ªAº:
118.7 mm (4.6732 in)
NEM328 Cylinder head bolt
12 mm
ªAº
CYLINDER HEADCD20T
Installation (Cont'd)
EM-152
Page 1693 of 2267
Tightening procedure
IApply engine oil to threads and underhead seating face of
each bolt.
Tighten bolts in the numerical order shown in the figure and follow-
ing the steps below.
pa31 - 37 N´m (3.2 - 3.8 kg-m, 23 - 27 ft-lb)
pbTighten to 180 - 190É
pcCompletely loosen the bolts in reverse order
pd31 - 37 N´m (3.2 - 3.8 kg-m, 23 - 27 ft-lb)
peTighten to 90 - 95É
pfTighten to 90 - 95É
3. Install rocker cover.
IInstall rocker cover in the sequence shown at left.
IApply sealing compound (THREE-BOND No. 10 or equivalent)
to both ends of brackets No. 1 and No. 5.SEM672D Engine front
SEM848F
NEM211 Marking
SEM678D
SEM677D Apply sealant.
CYLINDER HEADCD20T
Installation (Cont'd)
EM-153
Page 1694 of 2267

Selecting cylinder head gasket
When replacing only cylinder head gasket, install the same
grade (Number of notches) gasket as the one formerly used.
Step 1
Measure projection of piston to cylinder head surface.
a) Set dial gauge and needle on cylinder block and adjust dial
gauge to zero.
b) Set dial gauge needle at measuring point on piston, taking care
not to disturb its zero setting.
c) Rotate crankshaft around the top dead center position.
d) Record the maximum value.
e) Reset dial gauge on cylinder block and confirm that zero set-
ting has not been disturbed during measurement.
f) Repeat steps b through d for all measuring points as illustrated
and for each cylinder.
IBe sure that piston whose projection is being measured is at
its TDC.
Step 2
Calculate the average value of measurements taken for each pis-
ton.
Step 3
Calculate the average value of measurements for all pistons from
the values obtained from step 2.
Step 4
Round off the value obtained.
Step 5
Determine required thickness of gasket, referring to chart A.
Relation between piston average projection and cylinder head
gasket (Chart A)
Average value of
piston projections
mm (in)Gasket thickness
mm (in)Grade
(Number of
notches)
New parts In assembly
Less than 0.505
(0.0199)1.30 (0.0512)1.15
0.05
(0.0453 0.0020)1
0.505 - 0.555
(0.0199 - 0.0219)1.35 (0.0531)1.20
0.05
(0.0472 0.0020)2
Over 0.555 (0.0219) 1.40 (0.0551)1.25
0.05
(0.0492 0.0020)3
Step 6
Check if the average value of each projection obtained from step
2 is larger than the max. value of the standard projection (of
selected gasket) incremented by 0.05 mm (0.0020 in).
If so, use gasket that is 1 grade thicker. If not, use gasket as
selected in step 4.
SEM593A
SEM529D 30
(1.18)30
(1.18)
Unit: mm (in)
25
(0.98)25
(0.98)
SEM530D Notch
CYLINDER HEADCD20T
Installation (Cont'd)
EM-154
Page 1695 of 2267

Example
Unit: mm (in)
StepCylinder No.
Item1234
1.Measured
valueM1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4
0.53
(0.0209)0.56
(0.0220)0.53
(0.0209)0.56
(0.0220)0.59
(0.0232)0.55
(0.0217)0.59
(0.0232)0.55
(0.0217)0.53
(0.0209)0.58
(0.0228)0.57
(0.0224)0.54
(0.0213)0.58
(0.0228)0.51
(0.0201)0.52
(0.0205)0.57
(0.0224)
2.Average value
of each piston0.545
(0.0215)0.570
(0.0224)0.555
(0.0219)0.545
(0.0215)
3.Average value
of all pistons0.55375 (0.02180)
4.Round off
value0.554 (0.0218)*1
5.Determined
gasket thick-
ness (Tempo-
rarily)1.20 (0.0472) (Grade 2)
6.X: Maximum value of standard projection of selected gasket...0.555 (0.0219) (in chart A) + 0.05 (0.0020) = 0.605 (0.0238)
Y: Maximum value in step 2 = 0.57 (0.0224)
The relationship between X and Y is ªX > Yº. *2
7.Determined
gasket thick-
ness (Finally)1.20 (0.0472) (Grade 2)*2
*1: If the average value of projections for all pistons is, for example, 0.553 (7) 5, as shown in the table above, it should be rounded off as fol-
lows:
If the digit in the fourth decimal place (which is enclosed by a circle in this case) is smaller than 5, the average value should be regarded
as 0.553 mm (0.0218 in); if it is larger than 5, the average value should be regarded as 0.554 mm (0.0218 in).
*2: If X < Y, then the thicker grade 3 gasket must be used.
CYLINDER HEADCD20T
Installation (Cont'd)
EM-155
Page 1696 of 2267
Removal
1. Disconnect radiator lower hose and drain coolant.
2. Drain coolant from cylinder block.
3. Remove engine under cover.
4. Remove front exhaust tube.
5. Remove air inlet hose from turbocharger unit.
6. Remove connector bolts of turbocharger oil feed tube and
hoses for turbocharger water feed and return tubes.
7. Remove EGR tube.
8. Remove exhaust manifold cover.
9. Remove insulator.
10. Remove turbocharger oil return hose from oil pan.
11. Remove exhaust manifold fixing nuts and bolts.
NEM204
.Turbocharger water
return tube
.Turbocharger water
feed tube
.Turbocharger oil
feed tube
NEM202 Exhaust
manifold
coverAir inlet
hose EGR
tube
Insulator
.NEM203
.Turbocharger
oil return hose
.Oil pan
NEM205 Loosen in numerical order
p1p2
p3p4
TURBOCHARGERCD20T
Removal
EM-156