V2003 (S160) Valve adjustment

[otisdog]

Have the factory service manual, and I've never spent more for so little. It says to adjust the valves on a certain cylinder when another specified cylinders' rockers are 'loose'. But if the valves are out of adjustment, the rocker(s) aren't loose. I can't find a cylinder where both of the rockers are loose at the same time. Okay, we'll go to TDC...no we won't. Without tearing off of the front cover to get at the timing gears, you can't find any timing marks. Nowhere in my 5" thick factory service manual is TDC mentioned. I'm stunned, and rather pissed. I mean, that's why you buy the manuals, right? A search of the internet seems to only find more frustrated people. Only 4 or 5 posts anywhere, that I could find. Can any of you wizards out there provide enlightenment to me?

 

[foton]

Make sure the engine can not light off and try to go to the crank bolt with a socket and a breaker bar. Roll the engine over till the valves loosen up on one cylinder and do each one at a time is all I can think of.

 

[foton]

Make sure the engine can not light off and try to go to the crank bolt with a socket and a breaker bar. Roll the engine over till the valves loosen up on one cylinder and do each one at a time is all I can think of.

I should have mentioned that if you have a magnetic base dial indicator that you could find tdc by checking out the head design and going thru the injector hole or possibly a glow plug hole with a longish probe end on the dial indicator.

 

[otisdog]

I should have mentioned that if you have a magnetic base dial indicator that you could find tdc by checking out the head design and going thru the injector hole or possibly a glow plug hole with a longish probe end on the dial indicator.

Thanks for the response. I have no problem spinning the engine over...when I do, I can't find two rockers on any cylinder that are loose at the same time. So the manual directing me to "use the rocker arms rocking" on one cylinder to determine which adjacent cylinder to adjust the valves on is useless. Hence my frustration. As to using a rod in the cylinder to determine the top of the stroke...I think the angle of both the glow plug and injector in relation to the piston preclude an accurate tell. It just stuns me that there is zero mention of TDC in my 5" thick factory manual, and the only way to find it is to tear the front cover off to expose the timing gears -which means pulling the engine. I can go to any of my cars, and TDC is marked on the flywheel, front sprocket and camshaft.

 

[Hotrod1830]

Thanks for the response. I have no problem spinning the engine over...when I do, I can't find two rockers on any cylinder that are loose at the same time. So the manual directing me to "use the rocker arms rocking" on one cylinder to determine which adjacent cylinder to adjust the valves on is useless. Hence my frustration. As to using a rod in the cylinder to determine the top of the stroke...I think the angle of both the glow plug and injector in relation to the piston preclude an accurate tell. It just stuns me that there is zero mention of TDC in my 5" thick factory manual, and the only way to find it is to tear the front cover off to expose the timing gears -which means pulling the engine. I can go to any of my cars, and TDC is marked on the flywheel, front sprocket and camshaft.

Remove the glow plugs and roll it over with a ratchet while you have a finger over the glow plug hole. The compression stroke should force your finger off the hole. When the air stops, thats close to TDC. Remember, safely you have at least 180 degrees of crank movement with both valves closed on the compression/power cycle, so being exactly on TDC isnt a must. You have the valve cover off, so seeing the rocker arms move should help you count the strokes. 1: Intake, 2:compression,3ower,4:exhaust. Check the valve clearance on that cylinder. adjust as required and move to the next cylinder. After I adjust them all, I always repeat once to double check.

 

[otisdog]

Remove the glow plugs and roll it over with a ratchet while you have a finger over the glow plug hole. The compression stroke should force your finger off the hole. When the air stops, thats close to TDC. Remember, safely you have at least 180 degrees of crank movement with both valves closed on the compression/power cycle, so being exactly on TDC isnt a must. You have the valve cover off, so seeing the rocker arms move should help you count the strokes. 1: Intake, 2:compression,3ower,4:exhaust. Check the valve clearance on that cylinder. adjust as required and move to the next cylinder. After I adjust them all, I always repeat once to double check.

Thanks, Hotrod. Just what I needed. Was a little intimidated about pulling the glow plugs, but ended up pulling those and the injectors for the experience and to make cleaning up the area easier.

 

[Tazza]

Thanks, Hotrod. Just what I needed. Was a little intimidated about pulling the glow plugs, but ended up pulling those and the injectors for the experience and to make cleaning up the area easier.

Another way to find it, is to remove an injector line, rotate the engine over, with the fuel shit off solenoid engaged so fuel can flow till you see a small bubble of fuel appear. This small bit of fuel is about 15 degrees before TDC, so when you see the fuel appear, turn it a little more and then you will be TDC on that cylinder.
In direct injection engines, removig the glow plug will work for finding what cylinder is at the highest point with a probe, but keep in mind that being 4 strong, it could be 180 degrees out, just because it's at the top of stroke, the cam chaft can be 180 degrees away from being at TDC
Thankfully the older ones i have worked on have marks on the crank pulley, so you rotate till its lined up on a pointer and you know it's right.