VALVE CLEARANCE ADJUSTMENT [MZR 1.3, MZR 1.5]

id0110e1803300

1. Disconnect the negative battery cable.

2. Perform the following procedure.

Without set bolt

1. Remove the fresh-air duct and the air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

With set bolt

1. Set the air cleaner cover out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

2. Remove the fresh-air duct and the air cleaner case as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

3. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

4. Disconnect the ventilation hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

5. Set the vacuum hose out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

6. Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

7. Remove the splash shield (RH). (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

8. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

9. Remove the engine front cover blind plug as shown in the figure.

am3zzw00006281

10. Insert a M6 bolt (45 to 80 mm length bolt with threads to the end) into the service hole (right side) by hand as shown in the figure. Pull back the inserted bolt approx. 2 mm from where it contacts the tensioner arm, and set the bolt in a position slightly outward of the tensioner arm.

am2zzw00000094

11. Release tension on the timing chain.

(1) Press down the link plate of the chain tensioner from the service hole on the left side using a thin flathead screwdriver (precision screwdriver) as shown in the figure. Then rotate the crank pulley backwards (counterclockwise) with the plunger lock released.

am2zzw00000095

Note

• When the crankshaft pulley is turned counterclockwise, the timing chain loosens because the tensioner arm is pressed by the timing chain and the plunger of the chain tensioner is pressed in.

am2zzw00000096

(2) Insert the M6 bolt installed to the engine front cover to the position where it catches the inside of the rib on the tensioner arm.

am2zzw00000098

Note

• When the timing chain loosens, the tensioner arm moves to the position shown in the figure and presses the M6 bolt to secure the tensioner arm.

am2zzw00006237

12. Fix the camshaft using a wrench on the cast hexagon. Remove the camshaft sprocket installation bolt.

am2zzw00001662

13. Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way.

am2zzw00000100

14. Loosen the camshaft cap installation bolts in two or three steps in the order shown in the figure, and remove the camshaft caps.

am2zzw00001663

15. Remove the intake and exhaust camshafts.

16. Remove the tappet.

17. Select a proper tappet according to the result of the valve clearance inspection and install it.

Tappet to be selected: thickness of the removed tappet + measured valve clearance – standard valve clearance (IN: 0.3 mm {0.0118 in}, EX: 0.3 mm {0.0118 in})

Standard valve clearance [Engine cold]

IN: 0.27—0.33 mm {0.0107—0.0129 in}

EX: 0.27—0.33 mm {0.0107—0.0129 in}

18. Align the timing marks on the crank pulley and the front cover, and then align the No.1 cylinder to the TDC.

am2zzw00000102

19. Install the intake and exhaust camshafts with the No.1 cylinder so that it is near TDC of the compression stroke.

20. Install the camshaft caps to the position of a carved seal number to shown in the figure, and tighten the camshaft installation bolts in two or three steps uniformly in the order shown in the figure.

am2zzw00006883

Tightening torque

12—14 N·m {116—145 kgf·cm, 100—125 in·lbf}

21. Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

am2zzw00000104

22. Fix the camshaft using a wrench on the cast hexagon. Install the camshaft sprocket installation bolt.

Tightening torque

50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}

23. Remove the M6 bolt holding the tensioner arm.

24. Verify that there is no slack in the timing chain, and then verify that the marks on the camshaft sprocket and the crank pulley are aligned.

25. Inspect the valve timing by rotating the crankshaft clockwise twice.

26. Install the new engine front cover blind plug.

am3zzw00006281

Tightening torque

3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}

27. Install the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

28. Install the splash shield (RH). (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

29. Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

30. Connect the ventilation hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

31. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

32. Install the fresh-air duct and the air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)