VALVE CLEARANCE ADJUSTMENT [MZR 2.3 DISI Turbo]
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1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
3. Remove the charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
4. Remove the high pressure fuel pump and high pressure fuel pump cover. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
6. Disconnect the ventilation hose from the cylinder head cover. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
7. Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
8. 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.)
9. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
10. Remove the engine front cover lower blind plug.
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11. Remove the engine front cover upper blind plug.
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12. Remove the cylinder block lower blind plug.
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13. Rotate the crankshaft in the direction of the engine rotation until the No. 1 piston is at the point prior to top dead center (TDC) of the compression stroke.
14. Install the SST.
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15. 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 the SST and stops.)
16. Loosen the timing chain using the following procedure.
Ratchet unlock position
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17. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.
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18. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.
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19. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
20. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.
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21. Remove the camshafts for the intake and exhaust sides.
22. Remove the tappet.
23. Install an appropriate tappet based on the results of the valve clearance inspection.
24. Verify that the No.1 piston is at TDC of the compression stroke. (The position counterweight contacts the SST.)
25. 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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26. With No.1 cylinder cam aligned at TDC of the compression stroke, install the camshafts.
27. 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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28. Carefully apply sealant agent (Loctite 518 or 962T) 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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29. Temporarily tighten the camshaft cap bolts evenly in 2—3 steps.
30. Tighten the camshaft cap bolts in two steps in the order shown in the figure.
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31. Install the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
32. Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.
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33. Install the SST on the camshaft as shown in the figure.
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34. Remove the bolt (M6 X 1.0, length 25—35mm {1.0—1.3 in}) from the engine front cover upper blind plug hole, and apply tension to the timing chain.
35. Verify that the No.1 piston is at TDC of the compression stroke. (The position counterweight contacts the SST.)
36. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the camshaft sprocket bolt.
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37. Remove the SST from the camshaft.
38. Remove the SST installed to the cylinder block lower blind plug hole.
39. Rotate the crankshaft clockwise two turns and inspect the valve timing.
40. Install the cylinder block lower blind plug.
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41. Apply the silicone sealant and install the engine front cover upper blind plug.
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42. Install a new engine front cover lower blind plug.
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43. Install the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
44. 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.)
45. Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
46. Connect the ventilation hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
47. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
48. Install the high pressure fuel pump and high pressure fuel pump cover. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
49. Install the charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
50. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
51. Install the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)