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1.Remove the engine front cover lower blind plug.

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2.Remove the engine front cover upper blind plug.

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3.Remove the cylinder block lower blind plug.

4.Install the SST as shown in the figure.

Caution

• Removal of this SST is extremely important. If you crank the engine with this SST installed, the cylinder block will be damaged.

Cylinder block lower blind plug hole diameter: M8

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Cylinder block lower blind plug hole diameter: M10

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5.Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.

6.Loosen the timing chain.

(1)Insert a suitable bolt (M6 X 1.0, length 25—35mm {0.99—1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn.(Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)

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(2)Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.

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(3)Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.

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(4)Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.

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Note

• The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.

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Note

• The ratchet has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.

(5)Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.

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• If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.

7.Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.

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8.Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer (Type A bolt) as a single unit.

Caution

• Perform the work carefully so that the washer does not drop out. (Type A bolt)

• If a washer is not installed to the type A bolt, install a new washer.

Note

• A washer is not required to install to the type B bolt.

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9.Remove the oil control valve (OCV). (With variable timing mechanism.)

10.Loosen the camshaft cap bolts in several passes in the order shown in the figure.

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Note

• The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.

11.Remove the camshaft.

12.Remove the tappet.

13.Select proper adjustment shim.

New adjustment shim

= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in})

Valve clearance [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}

EX: 0.27—0.33 mm {0.0106—0.0130 in}

14.Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.

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15.Install the camshaft with No.1 cylinder aligned with the TDC position.

16.Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.

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17.Tighten the camshaft cap bolt using the following two steps.

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Tightening torque

(1) 5.0—9.0 N·m {51.0—91.7 kgf·cm, 44.3—79.5 in·lbf}

(2)14.0—17.0 N·m {1.43—1.73 kgf·m, 10.4—12.5 ft·lbf}

18.Install the OCV. (With variable value timing mechanism.)

Tightening torque

8.0—11.5 N·m {8.16—117.2 kgf·cm, 70.9—101.7 in·lbf}

19.Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer (Type A bolt) as a single unit.

Caution

• Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer. (Type A bolt)

• Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.

Note

• A washer is not required to install to the type B bolt.

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20.Install the SST to the camshaft as shown in the figure.

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21.Remove the M6 × 1.0 bolt from the engine front cover to apply tension to the timing chain.

22.Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.

23.Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.

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24.Tighten the exhaust camshaft sprocket lock bolt.

Tightening torque

69—75 N·m {7.1—7.6 kgf·m, 50.9—55.3 ft·lbf}

25.Remove the SST from the camshaft.

26.Remove the SST from the block lower blind plug.

27.Rotate the crankshaft clockwise two turns until the TDC position.

• If not aligned, loosen the camshaft sprocket lock bolt and repeat from Step 20.

28.Apply the silicone sealant and install the engine front cover upper blind plug.

Note

• Install the engine front cover upper blind plug before the applied silicone sealant starts to harden.

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Tightening torque

8.0—11.5 N·m {82—117 kgf·cm, 71—101 in·lbf}

29.Install the cylinder block lower blind plug.

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Tightening torque

18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}

30.Install the new engine front cover lower blind plug.

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Tightening torque

10—14 N·m {102—142 kgf·cm, 89—123 in·lbf}