VALVE CLEARANCE ADJUSTMENT [MZR 2.3 DISI Turbo]


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Warning
•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [MZR 2.3 DISI Turbo].)

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.

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 2.3 DISI Turbo].)
•  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 2.3 DISI Turbo].)

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 hole 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 (2).

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

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

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.

•  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}

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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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
0.5—1.5 mm {0.02—0.05 in}

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

Note
•  Do not tighten the bolts during this step.

30.  Tighten the camshaft cap bolts in two steps in the order shown in the figure.

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Tightening torque
Step 1: 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}
Step 2: 14—17 N·m {1.5—1.7 kgf·m, 11—12 ft·lbf}

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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Caution
•  Install a new 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.

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

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.

•  If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 33.

40.  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}

41.  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}

42.  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}

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].)