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Service Bulletin
Applies To:
02-047
September 17, 2002
1998–02 Passport – ALL
Cylinder Head Service
BACKGROUND
In the 1998 through 2002 Passport Service Manuals,
some of the information on cylinder head service,
timing belt installation, camshaft gear timing, and valve
adjustment is incomplete. For complete information,
use this service bulletin along with the appropriate
service manual and fuel & emissions manual.
REQUIRED SPECIAL TOOLS
NOTE: For additional special tools you may need, refer
to the appropriate service manual.
This service bulletin covers these topics:
• Cylinder head removal (page 1)
• Cylinder head disassembly (page 2)
• Camshaft inspection (page 2)
• Cylinder head installation (page 3)
• Timing belt removal (page 3)
• Engine timing (page 3)
• Timing belt installation (page 4)
• Camshaft subgear preloading, gear timing, and
camshaft installation (page 5)
• Valve adjustment (page 7)
• Valve Inspection Chart (page 10)
• Valve Shim Replacement Chart (page 11)
Universal Holder: T/N J-43041
Cylinder Head Bolts (16 required):
P/N 8-97011-998-2, H/C 4396446
Valve Shims (While 41 shims are available, the 10
sizes below will cover most valve adjustments):
Shim# (Size)
266 (2.66 mm)
270 (2.70 mm)
274 (2.74 mm)
278 (2.78 mm)
282 (2.82 mm)
286 (2.86 mm)
290 (2.90 mm)
294 (2.94 mm)
298 (2.98 mm)
302 (3.02 mm)
P/N
8-97149-275-0
8-97149-277-0
8-97149-279-0
8-97149-281-0
8-97149-283-0
8-97149-285-0
8-97149-287-0
8-97149-289-0
8-97149-291-0
8-97149-293-0
H/C
5514443
5514468
5514484
5514500
5514526
5514542
5514567
5514583
5514609
5514625
Holder Handle: T/N 07JAB-001020A
Gear Spring Lever: T/N J-42686
Valve Adjuster Holder: T/N J-42689-AH
Large Binder Clip (2 required): Commercially available
CYLINDER HEAD REMOVAL
NOTE: Page references are to the 2002 Passport
Service Manual and the 2002 Passport Fuel &
Emissions Manual.
1. Remove the hood (see page 8F-15 of the service
manual).
2. Disconnect the negative cable from the battery.
3. Remove the air cleaner (see page 6E2-543 of the
fuel & emissions manual).
PARTS INFORMATION
NOTE: For additional parts you need, refer to the Parts
Catalog.
Cylinder Head Cover Gaskets:
P/N 8-97170-239-1, H/C 5517909
Flange Holder: T/N 07RAB-TB4010B
4. Remove the radiator upper fan shroud (see page
6B-8 of the service manual).
5. Remove the drive belt tensioner and the drive belt
(see page 6B-11 of the service manual).
6. Remove the cooling fan assembly (4 bolts) and the
cooling fan pulley.
7. Remove the power steering pump (see page
2A-23 of the service manual).
8. Drain the engine coolant (see page 6B-5 of the
service manual).
9. Drain the engine oil.
10. Remove the crankshaft pulley:
• Attach the flange holder (T/N 07RAB-TB4010B)
with the holder handle (T/N 07JAB-001020A) to
the pulley.
• While holding the pulley with the tool, remove the
pulley bolt and the pulley.
• Install the pulley bolt. (When needed later, this
will allow you to turn the crankshaft by hand.)
11. Remove the cylinder head covers (see pages
6A-19 and 6A-21 of the service manual).
12. Remove the timing belt (see TIMING BELT
REMOVAL on page 3).
 2002 American Honda Motor Co., Inc. – All Rights Reserved
ATB 23043 (0209)
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CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment,
and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume
this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an
authorized Honda automobile dealer.
13. Remove the common chamber (see page 6A-22,
steps 2 thru 8, of the service manual).
14. Remove the exhaust manifolds (see pages 6A-24
and 6A-25 of the service manual).
15. Remove the cylinder heads:
• Loosen the head bolts in the sequence shown
below.
• Remove and discard the head bolts.
• Remove the cylinder heads.
CAMSHAFT INSPECTION
NOTE: Service manual page references are to the
2002 Passport Service Manual.
1. Inspect the camshaft journal oil clearances and
thrust clearances (see page 6A-62 of the service
manual). If any clearances are not within
specification, replace the cylinder head(s).
2. Inspect the camshaft lobe heights, journal
diameters, and runout (see page 6A-61of the
service manual). If any measurements are not
within specification, replace the camshaft(s).
3. If any camshaft or camshaft drive gear is seized, or
if the engine is seized from other mechanical
causes, inspect the camshaft drive gear dowel pins
and the camshaft gears.
• Check the dowel pins for damage, and replace
the drive gear assemblies as needed.
DOWEL PINS
CYLINDER HEAD DISASSEMBLY
NOTE:
• Whether you’re rebuilding a cylinder head or
assembling a new one, mark the position of each
camshaft bearing cap and valve train part before you
remove it. When you assemble the head, install the
marked parts in their original positions.
• Service manual page references are to the 2002
Passport Service Manual.
1. Remove the camshaft drive gear, camshafts, and
valve train parts, as needed, for inspection or repair
(see pages 6A-48 and 6A-49 of the service
manual).
2. Clean the bare head to remove all varnish, carbon,
and grime.
3. Check the cylinder head and gasket, and repair the
head if needed (see page 6A-49 of the service
manual).
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LEFT CAMSHAFT
DRIVE GEAR
RIGHT CAMSHAFT
DRIVE GEAR
• Inspect the camshaft gears for movement and
correct positioning on the camshafts. If the gears
are not stationary, or if their positions are
incorrect, replace the camshaft(s).
The keyway should align
with the top center of the
front cam lobes.
02-047
CYLINDER HEAD INSTALLATION
NOTE: Service manual page references are to the
2002 Passport Service Manual.
1. After making the needed inspections or repairs,
install the cylinder heads with new head bolts (see
page 6A-34 of the service manual).
2. Install all parts you removed in the reverse order of
removal (see page 6A-30 of the service manual).
TIMING BELT REMOVAL
NOTE: Left and right engine callouts are from the
driver’s seat.
1. Remove the timing belt covers in this order: right,
left, then lower.
2. Loosen (don’t remove) the tensioner pulley bolt.
TENSIONER
PULLEY
TENSIONER
PULLEY BOLT
LOWER
TENSIONER
BOLT
TENSIONER PUSHER
IDLER
PULLEY
BOLT
IDLER
PULLEY
CRANKSHAFT
TIMING PULLEY
3. Remove the idler pulley bolt, and let the idler pulley
pivot towards the crankshaft timing pulley.
4. Remove the lower tensioner bolt and the tensioner
pusher.
5. Carefully remove the timing belt from the pulleys.
2. Turn the right cylinder bank’s camshaft pulley
clockwise with a socket and ratchet. (The pulley
clicks and stops several times.) Stop the pulley
when its green mark aligns with the valve cover
timing mark.
NOTE: You may need to rotate the camshaft pulley
up to four complete turns before its green mark
aligns directly with the valve cover timing mark.
RIGHT CYLINDER BANK
VALVE COVER
TIMING MARK
GREEN MARK
3. Turn the left cylinder bank’s camshaft pulley
clockwise with a socket and ratchet. (The pulley
clicks and stops several times.) Stop the pulley
when its green mark aligns with the timing belt
cover bolt hole.
NOTE: You may need to rotate the camshaft pulley
up to four complete turns before its green mark
aligns directly with the bolt hole.
LEFT CYLINDER BANK
BOLT
HOLE
ENGINE TIMING
1. Turn the crankshaft timing pulley until its notch
aligns with the mark on the oil pump housing.
NOTE: The crankshaft timing pulley may have a
green mark 180 degrees from its keyway. Do not
use this mark to set the crankshaft position.
VALVE
COVER
TIMING
MARK
GREEN
MARK
OIL
PUMP
HOUSING
MARK
4. Rotate the left cylinder bank’s camshaft pulley
clockwise another 1/4 turn to align its green mark
with the valve cover timing mark.
PULLEY
NOTCH
02-047
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TIMING BELT INSTALLATION
NOTE:
• Do not install the timing belt until you are sure the
camshafts, camshaft pulleys, and crankshaft timing
pulley are in their correct “timed” positions.
• Left and right engine callouts are from the driver’s
seat.
1. With the green direction arrows on the timing belt
pointing clockwise, slip the belt over the right
camshaft pulley so its solid white line (the line
closest to the direction arrows) aligns with the mark
on the pulley. Secure the belt to the pulley with a
large binder clip.
SOLID WHITE LINE
4. Wrap the timing belt around the inner side of the
idler pulley, then slip the belt over the crankshaft
timing pulley with its dotted white line aligned to the
green mark on the crankshaft timing pulley.
NOTE: For correct belt stretch, the dotted line must
meet the green mark on the crankshaft timing
pulley at the 9 o’clock position. If there isn’t enough
slack to slip the belt over the pulley in the correct
position, turn the crankshaft a few degrees
counterclockwise, install the belt, then turn the
crankshaft back to the 9 o’clock position.
CRANKSHAFT TIMING PULLEY
BINDER CLIP
DOTTED WHITE LINE
GREEN MARK
2. Wrap the timing belt around the bottom of the water
pump pulley, and draw it tight.
3. Slip the timing belt over the left camshaft pulley so
its other solid white line (the one farthest from the
direction arrows) aligns with the mark on the pulley.
Secure the belt to the pulley with a large binder clip.
BINDER CLIP
SOLID WHITE LINE
5. Place the tensioner pusher in a soft-jawed vise,
then slowly compress the tensioner pusher pin until
it lines up with the two small holes in the tensioner
pusher housing.
HEAVY DUTY
PAPER CLIP
PIN
(Compressed.)
TENSIONER PUSHER
6. Insert a straightened heavy duty paper clip through
the holes in the housing. This will hold the pin in its
compressed position.
NOTE: A new tensioner pusher comes with its pin
held compressed by a special wire. If you install a
new tensioner pusher, save the wire for future use.
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02-047
7. Install the tensioner pusher:
• Install the lower bolt loosely.
• Push the tensioner pusher up against the
tensioner pulley, then install the upper bolt, and
torque it to 25 N.m (18 lb-ft).
• Torque the lower bolt to 25 N.m (18 lb-ft).
TENSIONER
PULLEY
UPPER BOLT
TENSIONER
PUSHER
LOWER BOLT
8. Remove the wire or paper clip from the tensioner
pusher, and remove the binder clips from the
camshaft pulleys.
9. Verify the timing belt is correctly installed:
• Rotate the crankshaft three complete turns (not
two turns, as stated in the service manual).
• Align the crankshaft timing pulley notch with the
mark on the oil pump housing.
• Check the green marks on both camshaft
pulleys; they should line up with the valve cover
timing marks.
NOTE: After you rotate the crankshaft, the solid
white lines on the belt will not align with the
camshaft pulley marks; this is normal.
PULLEY MARKS
11. Install the crankshaft pulley, and torque the bolt to
167 N.m (123 lb-ft).
12. Install any other parts you removed to replace the
timing belt.
CAMSHAFT SUBGEAR PRELOADING, GEAR
TIMING, AND CAMSHAFT INSTALLATION
NOTE:
• The Passport V6 engine has a “non-interference”
design. This means the valves never contact the
pistons, even when the valves or camshafts are not
correctly timed, or even if a valve is fully open and its
piston is at top dead center (TDC).
• The ratio between the camshaft drive gear and the
camshaft gears is 1.33 to 1. This means the timing
dots on a correctly timed camshaft will only align with
the dots on the camshaft drive gears every 4th turn
of the camshaft pulley.
• The left and right intake camshafts are different. On
the cam lobe side of the camshaft gear, the left
intake camshaft is marked “LI,” and it has dual timing
dots; the right intake camshaft is marked “RI,” and it
has a single timing dot.
• The left and right exhaust camshafts are the same.
On the cam lobe side of the camshaft gear, both
camshafts are marked “LE” and “RE,” and both have
dual timing dots and a single dot.
• Service manual page references are to the 2002
Passport Service Manual.
1. Before you install the camshafts, preload the
subgears (preloading must be done whenever you
remove the bearing caps from a camshaft):
• Make sure the spring is installed between the
camshaft gear and the subgear.
• With the camshaft held in a soft-jawed vise,
attach the gear spring lever (T/N J-42686) to the
subgear, then turn the subgear until its threaded
hole lines up with the hole in the camshaft gear.
• Lock the subgear to the camshaft gear with a
5 x 0.8 mm bolt through either side of the gear
hole.
• Preload the subgears on the other camshafts.
CAMSHAFT GEAR
GEAR SPRING
LEVER
VISE
CAMSHAFT
PULLEYS
CRANKSHAFT
TIMING PULLEY
PULLEY NOTCH
OIL PUMP
HOUSING MARK
10. Remove the crankshaft bolt, then install the lower,
the right, and the left timing belt covers. Torque the
cover bolts to 19 N.m (14 lb-ft).
02-047
SUBGEAR
BOLT
(Either side.)
5 of 12
2. On the right cylinder bank, turn the camshaft pulley
until its green mark is at 12 o’clock in relation to the
head surface, at the center of the head. Turning the
pulley brings the timing dots on the camshaft drive
gear into their correct position: to the left and right
of the gear’s centerline.
RIGHT CYLINDER BANK
VALVE COVER
TIMING MARK
12 o'clock
(At center of head.)
GREEN MARK
4. Install the intake and exhaust camshafts in the right
cylinder bank:
• Set the camshaft marked “RI” into the intake side
of the head. Make sure the single timing dot on
the camshaft gear aligns with the timing dot on
the camshaft drive gear.
• Set the camshaft marked “RE” and “LE,” into the
exhaust side of the cylinder bank, with “RE” at
the 12 o’clock position. Make sure the single
timing dot on the camshaft gear aligns with the
timing dot on the camshaft drive gear.
RIGHT BANK
(Cylinders 1, 3, and 5)
CENTERLINE
TIMING
DOTS
RI
RIGHT INTAKE
CAMSHAFT GEAR
RE
RIGHT EXHAUST
CAMSHAFT GEAR
RIGHT CAMSHAFT
DRIVE GEAR
INTAKE SIDE
SINGLE
TIMING DOTS
EXHAUST SIDE
3. On the left cylinder bank, turn the camshaft pulley
until its green mark is at 12 o’clock in relation to the
head surface, at the center of the head. Then turn
the pulley counterclockwise until its green mark
points close to the timing belt cover bolt hole.
Turning the pulley brings the timing dots on the
camshaft drive gear into their correct position: to
the left and right of the gear’s centerline.
LEFT CYLINDER BANK
12 o'clock
(At center of head.)
BOLT
HOLE
RIGHT CAMSHAFT
DRIVE GEAR
5. Install the left cylinder bank intake and exhaust
camshafts:
• Set the camshaft marked “LI” into the intake side
of the head. Make sure the dual timing dots on
the camshaft gear align with the timing dot on the
camshaft drive gear.
• Set the camshaft marked “LE” and “RE,” into the
exhaust side of the cylinder bank, with “LE” at the
12 o’clock position. Make sure the dual timing
dots on the camshaft gear align with the timing
dot on the camshaft drive gear.
LEFT BANK
VALVE
COVER
TIMING
MARK
GREEN
MARK
CENTERLINE
LE
LEFT EXHAUST
CAMSHAFT GEAR
TIMING
DOTS
LI
LEFT INTAKE
CAMSHAFT GEAR
BOLT HOLE
LEFT CAMSHAFT
DRIVE GEAR
EXHAUST SIDE
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DUAL
TIMING
DOTS
LEFT CAMSHAFT
DRIVE GEAR
INTAKE SIDE
02-047
6. Install the camshaft bearing caps in the same
locations and directions they were before you
removed them.
NOTE: On the right cylinder bank, the directional
arrows on the bearing caps should point towards
the front of the engine. On the left bank, the arrows
should point towards the rear of the engine.
7. Install the bearing cap bolts, then torque them to 10
N.m (7 lb-ft) in the sequence shown below.
INTAKE
EXHAUST
8. Remove the bolts used to hold the preload of the
camshaft subgears.
9. If not already done, inspect the camshaft thrust
clearances (see page 6A-62 of the service
manual). If any clearances are not within
specification, replace the cylinder head(s).
VALVE ADJUSTMENT
NOTE:
• Valve adjustment can be done either on-vehicle or
off-vehicle.
• To measure exhaust valves, you need a 0.25 mm
and a 0.35 mm feeler gauge.
• To measure intake valves, you need a 0.23 mm and
a 0.33 mm feeler gauge. Since these are odd sizes,
you may need to stack two gauges (for example,
0.11 mm and 0.12 mm to make 0.23 mm). If you do
this, make sure the gauges are clean and in good
condition. If you’re not sure the gauge stack is
correct, measure it with a micrometer.
• Service manual page references are to the 2002
Passport Service Manual.
On-Vehicle Valve Adjustment
1. Make a copy of the Valve Inspection Chart on
page 11.
2. Make a copy of the Valve Shim Replacement Chart
on pages 12 and 13, then tape the pages together,
side-by-side.
3. Remove the cylinder head covers (see pages
6A-19 and 6A-21 of the service manual).
4. Measure the valve clearances using the Go/No-Go
method (see the note below). The clearances must
be
• Intake valves: 0.28 mm ± 0.05 mm
• Exhaust valves: 0.30 mm ± 0.05 mm
NOTE:
• To measure with the Go/No-Go method, use two
feeler gauges, one to measure the smallest
allowable clearance, and the other to measure
the largest.
- If the small gauge fits and the large gauge
doesn’t, the valve adjustment is OK.
- If the small gauge doesn’t fit, or if the large
gauge slides easily, the valve needs
adjustment.
• The feeler gauges slide through the clearance
gap at a slight angle, making the drag a little
more than it would be on other engines.
5. For valves with the correct clearance, draw an “X”
in the appropriate circle on the Valve Inspection
Chart. For valves with incorrect clearances, write
down the clearance you measured in the circle.
VALVE INSPECTION CHART
Example for #1 Cylinder
#1
EX
IN
0.37mm
In this example, the clearance of the front
exhaust valve is incorrect (0.37 mm).
The clearance of the other three valves is OK.
6. If you need to replace a valve shim, turn the
crankshaft (or camshaft) until the cam lobe for the
valve points away from the valve.
02-047
7 of 12
7. Turn the valve tappet with a pick or a small
screwdriver until the tappet notch is within the
indentation in the head.
14. Insert the correct shim, number side down, into the
tappet. Make sure the shim is fully seated.
TAPPET NOTCH
SHIM
(Number side
faces down.)
INDENTATION
8. Turn the crankshaft (or camshaft) pulley clockwise
until the cam lobe presses the valve fully open.
9. On the tappet side closest to the bearing cap, insert
the valve adjuster holder (T/N J-42689-AH)
between the camshaft and the tappet. The tool
should rest on the edge of the tappet without
touching the shim.
16. Turn the crankshaft (or camshaft) pulley clockwise
until the cam lobe again points away from the
valve.
17. Recheck the valve clearance using the Go/No-Go
method (see step 4).
• If the clearance is OK, repeat steps 6 thru 17 for
the other valves needing adjustment.
• If the clearance is still incorrect, repeat steps 6
through 17 until it is correct, then adjust the
remaining valves.
18. Turn the camshaft pulleys until the single timing dot
(right cylinder bank) and dual timing dots (left
cylinder bank) align with the single timing dots on
the camshaft drive gears.
VALVE
ADJUSTER
HOLDER
19. Install the cylinder head covers with new gaskets
(see pages 6A-20 and 6A-21). Torque the cover
bolts to 9 N.m (6.5 lb-ft).
(Rotate into place
between tappet
and camshaft.)
Cam lobe down.
10. Slowly turn the crankshaft (or camshaft) pulley
counterclockwise so that when the valve closes,
the tool catches between the camshaft and the
tappet, holding the valve slightly open.
NOTE: Do not turn the crankshaft (or camshaft)
pulley too far or in the wrong direction. If you do,
you might break the tool, or worse yet, damage the
cylinder head.
11. Insert a pick or a small screwdriver into the tappet
notch, and pry out the shim.
12. Wipe off the shim, then write its number on the
Valve Inspection Chart for that valve and cylinder. If
there is no number on the shim, measure its
thickness with a micrometer, and write down the
measurement on the Valve Inspection Chart.
13. Follow the directions on the Valve Shim
Replacement Chart to select the correct shim.
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15. Release and remove the tool by turning the
crankshaft (or camshaft) pulley clockwise.
Off-Vehicle Valve Adjustment
1. Make a copy of the Valve Inspection Chart on
page 11.
2. Make a copy of the Valve Shim Replacement Chart
on pages 12 and 13, then tape the pages together,
side-by-side.
3. Measure the valve clearances using the Go/No-Go
method (see the note below). The clearances must
be
• Intake valves: 0.28 mm ± 0.05 mm
• Exhaust valves: 0.30 mm ± 0.05 mm
NOTE:
• To measure with the Go/No-Go method, use two
feeler gauges, one to measure the smallest
allowable clearance, and the other to measure
the largest.
- If the small gauge fits and the large gauge
doesn’t, the valve adjustment is OK.
- If the small gauge doesn’t fit, or if the large
gauge slides easily, the valve needs
adjustment.
• The feeler gauges slide through the clearance
gap at a slight angle, making the drag a little
more than it would be on other engines.
02-047
4. For valves with the correct clearance, draw an “X”
in the appropriate circle on the Valve Inspection
Chart. For valves with incorrect clearances, write
down the clearance you measured in the circle.
9. For each valve needing adjustment, do steps 10
thru 13.
10. Insert a pick or a small screwdriver into the tappet
notch, and pry out the shim.
11. Wipe off the shim, then write its number on the
Valve Inspection Chart for that valve and cylinder. If
there is no number on the shim, measure its
thickness with a micrometer, and write down the
measurement on the Valve Inspection Chart.
VALVE INSPECTION CHART
Example for #1 Cylinder
12. Follow the directions on the Valve Shim
Replacement Chart to select the correct shim.
#1
EX
IN
0.37mm
13. Insert the correct shim, number side down, into the
tappet. Make sure the shim is fully seated.
SHIM
In this example, the clearance of the front
exhaust valve is incorrect (0.37 mm).
The clearance of the other three valves is OK.
(Number side
faces down.)
5. Rotate the camshaft pulley until the dual timing dots
(exhaust camshaft) and single timing dot (intake
camshaft) align with the timing dots on the
camshaft drive gear.
6. Lock the camshaft gear to its subgear with a
5 x 0.8 mm bolt through either side of the hole in
the gears. This holds the spring-loaded subgear in
place so you can remove the camshaft. Do this for
each camshaft you need to remove.
Insert bolt here.
RI
RIGHT INTAKE
CAMSHAFT GEAR
RE
RIGHT EXHAUST
CAMSHAFT GEAR
14. Install the camshafts (see steps 2 thru 9 of
CAMSHAFT SUBGEAR PRELOADING, GEAR
TIMING, AND CAMSHAFT INSTALLATION).
15. Rotate the camshaft pulleys a few turns to ensure
the new shims are fully seated.
16. Recheck the clearances of the valves you adjusted
with the Go/No-Go method (see step 3). If any
clearances are incorrect, readjust them.
RIGHT CAMSHAFT
DRIVE GEAR
SINGLE TIMING DOTS
Insert bolt here.
LE
LEFT EXHAUST
CAMSHAFT GEAR
LI
LEFT INTAKE
CAMSHAFT GEAR
LEFT CAMSHAFT
DRIVE GEAR
DUAL TIMING DOTS
7. Remove the camshaft bearing caps, noting the
location and direction of each cap.
8. Remove the camshaft(s).
02-047
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VALVE INSPECTION CHART
EX
#5
IN
IN
#6
EX
EX
#3
IN
IN
#4
EX
EX
#1
IN
IN
#2
EX
Right Cylinder Bank
Left Cylinder Bank
FRONT OF ENGINE
Directions: Check the clearance of each valve (12 intake and 12 exhaust). If a valve’s clearance is correct, draw an
“X” in the circle that represents that valve. If its clearance is incorrect, measure the actual clearance, and write the
number in the circle for that valve.
NOTE: Left and right cylinder bank designations are from the driver’s seat.
10 of 12
02-047
VALVE SHIM REPLACEMENT CHART
Measured Clearance
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
0.18
0.20
0.22
0.24
0.26
Shim Removed
240
240
242
240
244
240
240
246
248
240
240
240
240
284
286
288
290
292
294
296
298
300
302
304
306
308
310
312
314
316
318
320
242
242
244
244
244
244
244
244
240
240
242
244
240
240
266
282
242
240
264
280
242
240
240
262
278
242
240
260
276
242
240
258
274
244
240
240
256
272
242
242
240
252
270
240
244
244
240
240
250
268
242
240
254
Example:
#268 shim
removed
242
242
244
240
240
242
244
240
242
244
240
244
246
242
246
242
246
248
244
248
250
248
252
250
254
250
254
256
252
256
254
258
256
256
260
262
264
260
264
262
268
264
268
270
266
270
268
272
268
272
274
270
274
278
274
278
276
280
282
278
282
280
286
282
286
284
286
290
288
292
288
292
290
292
294
300
296
296
300
296
298
300
300
302
302
304
308
304
308
304
308
310
306
312
308
310
314
310
314
310
312
316
312
316
312
308
312
308
308
314
310
306
312
312
308
306
310
310
306
306
304
308
304
304
310
310
306
302
308
308
304
302
306
306
302
302
300
304
300
300
306
306
302
306
306
302
306
300
304
300
304
304
300
304
298
304
298
304
304
300
298
302
302
298
298
296
300
296
296
302
302
298
302
302
298
298
302
298
302
296
302
296
300
296
300
300
296
300
294
300
294
300
300
296
294
298
298
294
294
292
296
292
292
298
298
294
298
298
294
294
298
294
294
298
294
298
292
298
292
298
292
290
296
296
290
294
294
290
292
296
296
292
296
296
292
296
296
292
292
296
292
296
290
296
290
294
290
294
294
290
290
294
290
294
288
294
288
292
288
292
292
288
292
286
290
288
290
294
290
294
294
290
294
288
288
292
288
292
294
286
290
286
290
292
288
292
292
288
288
292
288
292
286
292
286
290
286
290
290
286
286
284
284
286
290
284
288
288
284
288
282
286
282
282
284
288
288
284
284
290
290
286
290
290
286
286
290
286
290
284
290
284
282
288
288
286
282
286
286
282
284
288
288
284
288
288
284
288
288
284
288
282
286
282
282
280
282
286
282
286
286
282
286
280
284
280
286
286
282
280
284
284
280
280
278
282
278
278
284
284
280
280
284
286
278
282
278
282
284
280
284
284
280
280
278
282
280
282
282
278
276
276
280
276
276
274
278
274
278
280
280
276
276
278
282
282
278
278
284
284
280
284
284
280
284
278
276
282
282
280
274
280
280
276
274
278
278
274
274
276
280
280
276
278
282
282
278
274
276
280
278
272
278
278
274
274
278
280
272
272
272
274
278
272
276
276
272
276
270
274
270
270
272
276
276
276
272
276
276
272
276
278
274
276
280
280
276
272
274
270
272
276
278
278
274
274
276
272
272
276
272
276
270
274
274
270
270
274
276
268
272
268
272
274
270
272
270
270
274
270
274
274
274
270
272
268
274
274
270
268
272
272
268
268
266
270
266
266
272
272
268
268
272
268
268
272
268
270
272
266
270
266
266
270
266
266
264
270
264
270
270
266
264
268
268
264
264
262
266
262
262
268
268
264
268
268
264
268
270
270
266
266
268
272
264
270
270
266
264
268
268
264
264
266
270
262
268
268
264
262
262
264
268
262
266
262
266
266
262
266
260
266
260
266
266
260
264
264
260
262
258
262
258
258
260
264
260
264
264
260
260
262
266
258
264
264
260
264
266
266
262
266
266
262
266
260
258
260
264
264
264
260
262
260
262
262
258
258
262
258
258
262
258
260
262
256
262
262
258
258
262
258
260
262
264
256
256
260
262
258
254
258
258
256
256
262
252
254
254
260
252
256
256
258
260
256
256
260
256
256
254
260
250
254
258
258
254
254
260
260
256
260
260
256
256
260
260
254
258
254
254
258
258
252
256
252
254
252
258
258
254
258
258
254
258
252
256
256
252
256
256
252
252
256
252
256
250
256
250
254
250
254
254
250
250
254
250
254
248
254
248
252
248
252
252
248
248
252
248
252
246
252
246
256
252
254
256
250
254
250
252
252
248
252
248
252
254
254
254
250
254
248
250
250
246
248
252
246
250
250
246
250
252
252
252
248
252
246
248
248
244
246
250
250
250
250
246
250
244
246
246
248
244
248
244
248
248
244
244
248
248
248
248
250
246
250
250
246
246
244
242
244
244
244
248
248
244
244
250
250
246
242
248
248
244
246
242
246
246
242
246
242
246
246
242
246
242
242
242
246
242
246
242
246
246
242
314
318
314
316
Directions:
Intake
Exhaust
02-047
• Find the clearance that you measured along the top row of the chart and draw a line
down the column.
• Find the number of the shim you removed down the left hand column of the chart
and draw a line to the right along the row.
• Find the number of the correct replacement shim in the box where the two lines meet.
11 of 12
VALVE SHIM REPLACEMENT CHART
Example: Measured clearance
0.38mm - exhaust valve
0.28
240
0.30
0.32
242
244
244
246
246
248
242
242
0.34
246
244
244
250
250
252
246
245
252
252
254
254
256
250
256
256
258
258
260
254
260
256
256
258
262
258
260
262
262
264
258
264
260
260
266
262
266
268
262
264
264
270
270
272
266
268
268
270
274
270
272
274
274
276
276
278
270
276
272
272
274
278
280
276
282
282
282
284
284
286
278
280
280
282
286
288
288
290
284
290
290
292
292
294
288
288
294
292
296
292
294
296
296
298
292
294
294
298
302
320
320
316
318
320
316
318
320
316
318
320
316
318
320
316
318
320
316
318
320
318
320
308
308
310
310
310
312
312
314
314
310
314
316
316
318
318
314
318
316
318
318
318
318
318
318
318
318
318
314
314
314
314
314
314
314
314
314
314
316
316
316
316
316
316
316
316
312
312
312
312
312
312
312
312
312
314
314
314
314
314
310
310
310
310
310
310
312
312
312
312
308
308
308
308
308
310
306
306
306
320
318
308
310
306
312
308
314
310
316
312
314
318
320
318
308
304
310
306
312
308
314
310
312
318
316
320
316
316
308
304
310
306
312
308
310
316
314
318
314
316
306
304
306
314
312
316
312
314
318
320
308
304
310
306
308
310
314
310
316
320
306
304
312
314
312
316
312
318
306
302
302
304
308
310
314
310
318
306
302
308
304
306
312
312
308
308
310
314
316
304
304
302
306
310
306
312
312
308
308
312
308
316
304
300
306
302
304
310
306
310
306
306
310
306
306
310
320
304
300
302
304
310
304
304
304
310
304
308
308
308
304
308
308
304
308
308
304
308
302
306
302
302
306
302
302
306
302
306
306
302
306
302
318
302
300
306
300
306
306
302
304
300
300
304
300
304
304
304
300
302
300
304
300
318
300
300
300
304
300
298
302
304
300
298
298
302
298
298
302
302
296
298
302
316
302
298
302
298
298
300
298
304
298
304
296
298
302
302
298
302
302
298
302
296
300
300
296
300
296
296
316
300
298
296
300
300
296
300
300
296
296
300
296
296
294
300
294
298
300
296
298
296
300
300
300
296
294
298
294
294
294
298
294
294
294
294
292
292
298
298
292
296
296
292
292
290
294
290
290
296
296
296
292
296
298
298
294
298
298
294
298
298
294
298
292
292
292
290
292
296
290
294
294
290
294
296
296
292
296
296
292
290
290
288
290
294
294
294
290
290
296
288
288
292
288
294
288
294
294
290
288
292
292
288
288
286
290
286
286
292
292
288
292
292
292
288
288
292
292
294
294
290
290
290
292
292
288
290
292
288
290
286
286
286
290
286
290
290
290
286
286
286
286
284
284
290
284
290
290
286
284
288
288
284
284
282
286
282
282
288
288
284
288
288
284
284
288
288
284
288
290
290
286
286
286
284
284
282
284
288
282
286
286
282
286
288
288
284
280
282
286
286
282
282
284
280
282
288
282
286
282
286
286
282
286
280
286
280
286
286
282
280
284
284
280
280
278
282
278
278
284
284
280
284
284
280
280
284
280
284
284
284
280
280
284
278
278
278
282
278
282
282
282
278
278
280
276
276
276
280
276
280
280
280
276
274
278
274
278
278
274
274
272
276
272
278
284
278
282
278
282
282
278
282
276
282
276
282
282
276
280
280
276
278
274
278
274
274
276
280
276
280
280
276
276
280
276
280
274
280
274
278
274
278
278
274
274
278
274
278
272
278
272
276
272
276
276
272
272
276
272
276
270
276
270
274
270
274
274
270
270
274
270
274
268
274
268
272
268
272
272
268
268
272
268
272
266
272
266
270
266
270
270
266
266
270
266
268
264
270
264
268
264
268
268
264
268
262
266
262
266
266
262
264
260
264
260
272
272
278
280
270
276
276
278
274
268
274
270
272
272
278
268
270
276
0.58
270
272
274
274
276
272
266
272
268
270
270
276
266
268
274
0.56
268
270
272
272
274
270
264
270
266
268
268
274
264
266
272
0.54
266
268
270
270
272
268
262
268
264
266
266
272
262
264
270
0.52
264
266
268
268
270
266
260
266
262
264
264
270
260
262
268
0.50
262
264
266
266
268
264
258
264
260
262
262
268
258
260
266
0.48
260
262
264
264
266
262
256
262
258
260
260
266
256
258
264
0.46
258
260
262
262
264
260
254
260
256
258
258
264
254
256
262
0.44
256
258
260
260
262
258
252
258
254
256
256
262
252
254
260
0.42
254
256
258
258
260
256
250
256
252
254
254
258
254
250
252
258
0.40
252
254
256
256
252
248
254
250
250
252
252
248
254
254
250
0.38
250
252
252
248
248
248
246
250
250
246
248
244
248
0.36
248
320
320
320
320
320
320
320
320
320
320
320
320
320
318
320
Example:
• You measure 0.38 mm clearance on an exhaust valve.
• You remove a #268 shim.
• The correct replacement shim is a #276.
12 of 12
02-047