VALVE CLEARANCE ADJUSTMENT [MZR 2.0 DISI i-stop]

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1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

4. Disconnect the wiring harness.

5. Remove the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

6. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

7. Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

8. Remove the ventilation hose.

9. Remove the dipstick.

10. Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

11. Remove the aerodynamic under cover No.2 and splash shield as a single unit. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

12. Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

13. Remove the engine front cover lower blind plug.

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14. Remove the engine front cover upper blind plug.

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15. Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

16. Remove the cylinder block lower blind plug, and install the SST.

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17. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the compression stroke. (Until the counterweight contacts SST and stops.)

18. Loosen the timing chain using the following procedure:

Note

• Verify the ratchet position using the mirror before servicing. If the ratchet is not tilted, remove the engine front cover before performing the procedure. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

• If the timing chain tension cannot be released with the ratchet tilted, remove the engine front cover before performing the procedure. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

Ratchet unlock position

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(1) Insert a suitable bolt (M6 X 1.0, length 25—35 mm {1.0—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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(5) Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.

Note

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

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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.

19. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.

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20. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.

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Caution

• Perform the work carefully so that the washer does not drop out.

21. Remove the oil control valve (OCV). (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

22. Loosen the camshaft cap bolts in two or three passes in the order shown in the figure and remove the camshaft cap.

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Note

• The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.

23. Remove the camshafts for the intake and exhaust sides.

24. Remove the tappet.

25. Install an appropriate tappet based on the results of the valve clearance inspection.

Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance

Valve clearance for inspection [Engine cold]

IN: 0.22—0.30 mm {0.009—0.011 in}

EX: 0.27—0.37 mm {0.011—0.014 in}

26. Verify that the No.1 cylinder is at TDC of the compression stroke. (The position counterweight contacts the SST.)

27. 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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28. Install the camshaft with No.1 cylinder cam aligned at TDC of the compression stroke.

29. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure. However, do not apply it to the end journal of the intake camshaft.

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30. Carefully apply sealant agent (Loctite 518 or 962) to the area indicated in the figure so that it does not leak into the sliding part then, apply the gear oil (SAE No. 90 or equivalent) to the journal.

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Note

• To prevent engine oil leakage, apply sealant to the rear camshaft cap on the intake side and seal the journal.

Sealan agent bead width

1.0 mm {0.039 in}

31. Temporarily tighten the camshaft cap bolts evenly in 2—3 steps.

Note

• Do not tighten the bolts during this step.

32. Tighten the camshaft cap bolts in the order shown in the following two steps.

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Tightening procedure

1st step: 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}

2nd step: 14—17 N·m {1.5—1.7 kgf·m, 11—12 ft·lbf}

33. Install the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

34. Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

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Caution

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

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

35. Install the SST on the camshaft as shown in the figure.

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36. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25—35mm {1.0—1.3 in}), and apply tension to the timing chain.

37. Verify that the No.1 cylinder is at TDC of the compression stroke. (The position counter weight contacts the SST.)

38. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.

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Tightening torque

69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}

39. Remove the SST from the camshaft.

40. Remove the SST installed in the cylinder block lower blind plug hole.

41. Rotate the crankshaft clockwise two turns and inspect the valve timing.

• If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 35.

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

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Note

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

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

43. Install the cylinder block lower blind plug.

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Tightening torque

18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}

44. Install a 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}

45. Connect the drive shaft (RH) to joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

46. Install the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

47. Install the aerodynamic under cover No.2 and splash shield as a single unit. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

48. Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

49. Install the dipstick.

50. Install the ventilation hose.

51. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

52. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

53. Install the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

54. Connect the wiring harness.

55. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

56. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

57. Install the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)