1. |
Disconnect the breather hose and the P.C.V.
hose.

|
2. |
Remove the coolant pump pulley and crankshaft
pulley.


|
3. |
Remove the timing belt cover.


|
4. |
Loosen the timing belt tensioner pulley and
temporarily secure it.

|
5. |
Remove the timing belt from the camshaft
sprocket.

|
6. |
Remove the ignition coil
assembly. |
7. |
Loosen the cylinder head cover bolts and then
remove the cylinder head cover.

|
8. |
Remove the camshaft sprocket.

|
9. |
Remove the camshaft bearing caps and timing
chain.

|
11. |
Remove the mechanical tappets and
shims.

Arrange the mechanical tapets and shims
in correct
order. | |
12. |
Remove the OCV (Oil control
valve).

|
13. |
Remove the OCV filter

|
1. |
Check the camshaft journals for wear. If the
journals are badly worn, replace the
camshaft. |
2. |
Check the cam lobes for damage. If the lobe is
damaged or worn excessively, replace the camshaft.
Cam
height
W/O - CVVT
[Standard value]
Intake : 44.820 mm (1.7646
in.)
Exhaust : 44.720 mm (1.7606
in.)
[Limit]
Intake : 44.720 mm (1.7606
in.)
Exhaust : 44.620 mm (1.7567
in.)
W - CVVT
[Standard value]
Intake : 44.618mm
(1.7566in.)
Exhaust : 44.518mm
(1.7527in.)
[Limit]
Intake : 44.518mm
(1.7527in.)
Exhaust : 44.418mm
(1.7587in.)
|

|
3. |
Check the cam surface for abnormal wear or
damage, and replace if necessary. |
4. |
Check each bearing for damage. If the bearing
surface is excessively damaged, replace the cylinder head assembly
or camshaft bearing cap, as necessary.
Camshaft end play : 0.1 ~ 0.2 mm (0.004
~ 0.008 in.)
|

|
CVVT ASSEMBLY
1. |
Inspect CVVT assembly.
(1) |
Check that the CVVT assembly will not
turn. |
(2) |
Apply vinyl tape to all the parts except
the one indicated by the arrow in the
illustration.

|
(3) |
Wind tape around tip of the air gun and
apply air of approx. 100kpa (1kgf/cm², 14psi) to the port of
the camshaft.
(Perform this order to release the lock
pin for the maximum delay angle locking.)
When the oil splashes, wipe if off
with a shop rag and the
likes. | |
(4) |
Under the condition of (3), turn the
CVVT assembly to the advance angle side (the arrow markded
direction in the illustration) with your hand.
Depending on the air pressure, the CVVT
assembly will turn to the advance side without applying force
by hand. Also, under the condition that the pressure can be
hardly applied because of the air leakage from the port, there
may be case that the lock pin could be hardly
released. |
(5) |
Except the position where the lock pin
meets at the maxuimum delay angle, let the CVVT assembly turn
back and forth and check the movable range and that there is
disturbance.
Standard : Movable smoothly in the
range about 20°
| |
(6) |
Turn the CVVT assembly with your hand
lock it at the maximum delay angle
position. | |
CAMSHAFT OIL SEAL
1. |
Check the lips for wear. If the lip threads
are worn, replace. |
2. |
Check the oil seal lip contacting surface of
the camshaft. If it is worn, replace the
camshaft. |
MLA (MECHANICAL LASH ADJUSTER)
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT

Inspect and adjust the valve clearance when
the engine is cold (Engine coolant temperature : 20°C) and cylinder
headis installed on the cylinder
block. |
1. |
Remove the engine cover.

|
2. |
Remove the upper timing belt
cover.

A. |
Loosen the upper timing belt cover bolts
and then remove the
cover. | |
3. |
Remove the cylinder head cover.
A. |
Disconnect the spark plug cables and do
not pull on the spark plug cables by force.
Pulling on or bending the cables
may damage the conductor
inside. | |
B. |
Disconnect the P.C.V. hose and the
breather hose from the cylinder head cover.

|
C. |
Disconnect the accelerater cable from
the cylinder head cover.

|
D. |
Loosen the cylinder head cover bolts and
then remove the cover and gasket.

| |
4. |
Set No.1 cylinder to TDC/
compression.
A. |
Turn the crankshaft pulley and align its
groove with the timing mark "T" of the lower timing belt
cover.

|
B. |
Check that the hole of the camshaft
timing pulley is aligned with the timing mark of the bearing
cap. If not, turn the crankshaft one
revolution(360°)

| |
5. |
Inspect the valve clearance.
A. |
Check only the valves indicated as
shown. [No.1 cylinder : TDC/Compression] measure the valve
clearance

|
•
|
Using a thickness gauge, mesure
the clearance between the tappet shim and the base
circle of camshaft. |
•
|
Record the out-of-specification
valve clearance measurements. They will be used later to
determine the required replacement adjusting
shim.
Valve clearance
[Specification]
Engine coolant temperature :
20°C (68°F)
Intake : 0.20mm (0.0079
in.)
Exhaust : 0.28mm (0.0110
in.)
Engine coolant temperature :
80°C (176°F)
Intake : 0.29mm
(0.0114in.)
Exhaust : 0.34mm
(0.0134in.)
Limit
Intake : 0.12 ~ 0.28 mm
(0.0047 ~ 0.0110 in.)
Exhaust : 0.20 ~ 0.38 mm
(0.0079 ~ 0.0150 in.)
| | |
B. |
Turn the crankshaft pulley one
revolution (360°) and align the groove with timing mark "T" of
the lower timing belt cover. |
C. |
Check only the valves indicated as
shown. [NO.4 cylinder : TDC/compression]. Measure the valve
clearance. (See procedure in step (6))

| |
6. |
Adjust the intake and exhaust valve
clearance.
A. |
Turn the crankshaft so that the cam lobe
of the camshaft on the adjusting valve is
upward. |
B. |
Using the special tool (09220-2D000),
press down the valve lifter and place the stopper between the
camshaft and valve lifter and remove the special
tool.

|
C. |
Remove the adjusting shim with a small
screw driver and magnet.

|
D. |
Measure the thickness of the removed
shim using a micrometer.

|
E. |
Caculate the thickness of a new shim so
that the valve clearance comes within the specified
value.
Valve
clearance (Engine coolant temperature :
20°C)
T : Thickness of removed
shim
A : Measured valve
clearance
N : Thickness of new
shim
Intake : N = T + [A - 0.20 mm
(0.0079 in.)]
Exhaust : N = T + [A - 0.28 mm
(0.0110 in.)]
| |
F. |
Select a new shim with a thickness as
close as possible to the caculated value. [Refer to the
Adjusting shim selection chart]
Shims are available in 20 size
increments of 0.04 mm (0.0016 in.) from 2.00 mm (0.079
in.) to 2.76 mm (0.1087
in.) | |
G. |
Place a new adjusting shim on the valve
lifter. |
H. |
Using the special tool (09220 - 2D000),
press down the valve lifter and remove the
stopper. |
I. |
Recheck the valve
clearance.
Valve
clearance (Engine coolant temperature :
20°C)
[Specification]
Intake : 0.20 mm (0.0079
in.)
Exhaust : 0.28 mm (0.0110
in.)
[Limit] (After adjusting valve
clearance)
Intake : 0.17 ~ 0.23 mm (0.0067 ~
0.0091 in.)
Exhaust : 0.25 ~ 0.31 mm (0.0098 -
0.0122 in.)
|


| |
1. |
Install OCV filter.
Tightening
torque
41 ~ 51Nm (410 ~ 510kgf.cm, 30 ~
37lbf.ft)
|

Always use a new OCV filter gasket keep
clean the OCV
filter. | |
2. |
Install OCV.
Tightening
torque
10 ~ 12Nm (100 ~ 120kgf.cm. 7.3 ~
8.816lbf.ft)
|

•
|
Do not reuse the OCV when
dropped. |
•
|
Do not hold the OCV sleeve during
servicing. |
•
|
When the OCV is installed on the
engine, do not move the engine with holding the OCV
yoke. | | |
3. |
Install the camshaft.
(1) |
Align the camshaft timing chain with the
intake timing chain sprocket as shown.

|
(2) |
Install the camshafts and bearing
caps.
Tightening torque
14 ~ 15Nm (140 ~ 150kgf.cm, 10 ~
11lbf.ft)
|

|
(3) |
Install the timing chain auto
tensioner.

|
(4) |
Remove the auti tensioners stopper
pin. | |
4. |
Check and adjust valve
clearance. |
5. |
Using the SST (09221-21000), install the
camshaft bearing oil seal.

|
6. |
Install the camshaft
sprocket. |
7. |
Install the timing
belt. |
8. |
Install the cylinder head cover.
(1) |
Install the cylinder head cover gasket
in the groove of the cylinder head cover.

• |
Before installing the head
cover gasket, thoroughly clean the head cover
gasket and the
groove. |
• |
When installing, make sure
the head cover gasket is seated securely in the
corners of the recesses with no
gap. | | |
(2) |
Apply liquid gasket to the head cover
gasket at the corners of the recess.

• |
Use liquid gasket, loctite
No. 5999. |
• |
Check that the mating
surfaces are clean and dry before applying liqued
gasket. |
• |
After assembly, wait at
least 30 minutes before filling the engine with
oil. | | |
(3) |
Install the cylinder head cover with the
12 bolts. Uniformly tighten the bolts in several
passes.
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~
7.4lbf.ft)
|

| |
9. |
Connect the accelerater
cable. |
10. |
Connect the PCV hose and the breather hose to
the cylinder head cover. |
11. |
Connect the spark plug calbes to the spark
plugs. |
12. |
Install the upper timing belt cover with the
four bolts. |
13. |
Install the engine
cover. |