VALVE CLEARANCE ADJUSTMENT [L3]

R.H.D. models

1. Disconnect the negative battery cable.

2. Disconnect the high tension leads from the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [L3].)

3. Remove the splash shield (RH).

4. Remove the front wheel and tire (RH).

5. Remove the pressure pipe bracket of the P/S oil pump.

6. Loosen the pressure pipe joint bolt of the P/S oil pump, move the pressure pipe to the right side of the vehicle, position the cylinder head cover out of the way, and then temporarily tighten the bolt.

7. Remove the cylinder head cover.

8. Remove the drive belt. (See DRIVE BELT REPLACEMENT [L3].)

9. Remove the engine front cover lower blind plug.

10. Remove the engine front cover upper blind plug.

11. Remove the cylinder block lower blind plug.

12. Install the SST as shown.

13. Turn the crankshaft clockwise the crankshaft is in No.1 cylinder TDC position.

14. Loosen the timing chain using the following procedure.

(1) Insert a suitable bolt (M6 X 1.0, length 25-35 mm {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.)

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

(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.

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

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.

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.

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

15. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.

Caution

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

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

17. Loosen the camshaft cap bolts in two or three steps in the order shown.

Note

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

18. Remove the camshaft.

19. Remove the tappet.

20. Select proper 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})

IN: 0.22-0.28 mm {0.0087-0.0110 in} (0.25±0.03 mm {0.0098±0.0011 in})

EX: 0.27-0.33 mm {0.0107-0.0129 in} (0.30±0.03 mm {0.0118±0.0011 in})

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

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

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

24. Tighten the camshaft cap bolt with the following two steps.

(1) Tighten to 5.0-8.0 N·m {51.0-81.5 kgf·cm, 44.3-59.0 in·lbf}.

(2) Tighten to 14.0-17.0 N·m {1.5-1.7 kgf·m, 10.4-12.5 ft·lbf}.

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.

25. Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

26. Install the SST to the camshaft as shown.

European countries

Except European countries

27. Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain.

28. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST).

29. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.

30. Tighten the exhaust camshaft sprocket bolt.

Tightening torque:

69- 75N·m {7.1- 7.6 kgf·cm, 50.9-55.3 in·lbf}

31. Remove the SST from the camshaft.

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

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

• If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 26.

34. Apply silicone sealant to the engine front cover upper blind plug.

35. Install the engine front cover upper blind plug.

Tightening torque:

8.0- 11.5N·m {81.6-117.2 kgf·cm, 70.9-101.7 in·lbf}

36. Install the cylinder block lower blind plug.

Tightening torque:

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

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

Tightening torque:

10.0- 14.0N·m {1.0 -1.4kgf·m, 7.4 -10.3ft·lbf}

38. Install the drive belt. (See DRIVE BELT REPLACEMENT [L3].)

39. Install the splash shield (RH).

40. Install the front wheel and tire(RH).

41. Install the cylinder head cover. (See Cylinder Head Cover Installation Note.)

42. Loosen the pressure pipe joint bolt, move the pressure pipe joint until it contacts the stopper to return the pipe to its original position and then tighten the bolt.

Caution

• It is not necessary to replace the pressure hose joint seal and washer if only performing this procedure.A small amount of P/S fluid will leak from the joint.However,it is not necessary to perform the normal air bleeding procedure since air bleeding will occur when running the engine.

Tightening torque:

29.4- 44.1N·m {3.0- 4.4 kgf·m, 21.7-32.5ft·lbf}

43. Install the pressure pipe bracket of the P/S oil pump.

44. Disconnect the high-tension cord.(See SPARK PLUG REMOVAL/INSTALLATION [L3].)

L.H.D. models

1. Disconnect the negative battery cable.

2. Remove the ignition coil.

3. Remove the splash shield (RH).

4. Remove the front wheel and tire(RH).

5. Remove the cylinder head cover.

6. Remove the drive belt. (See DRIVE BELT REPLACEMENT [L3].)

7. Remove the engine front cover lower blind plug.

8. Remove the engine front cover upper blind plug.

9. Remove the cylinder block lower blind plug.

10. Install the SST as shown.

11. Turn the crankshaft clockwise the crankshaft is in No.1 cylinder TDC position.

12. Loosen the timing chain using the following procedure.

(1) Insert a suitable bolt (M6 X 1.0, length 25-35 mm {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.)

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

(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.

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

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.

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.

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

13. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.

Caution

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

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

15. Loosen the camshaft cap bolts in two or three steps in the order shown.

Note

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

16. Remove the camshaft.

17. Remove the tappet.

18. Select proper 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})

IN: 0.22-0.28 mm {0.0087-0.0110 in} (0.25±0.03 mm {0.0098±0.0011 in})

EX: 0.27-0.33 mm {0.0107-0.0129 in} (0.30±0.03 mm {0.0118±0.0011 in})

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

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

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

22. Tighten the camshaft cap bolt with the following two steps.

(1) Tighten to 5.0-9.0 N·m {51.0-91.7 kgf·cm, 44.3-79.5 in·lbf}.

(2) Tighten to 14.0-17.0 N·m {1.5-1.7 kgf·m, 10.4-12.5 ft·lbf}.

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.

23. Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

24. Install the SST to the camshaft as shown.

European countries

Except European countries

25. Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain.

26. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST).

27. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.

28. Tighten the exhaust camshaft sprocket bolt.

Tightening torque:

69- 75N·m {7.1- 7.6 kgf·cm, 50.9-55.3 in·lbf}

29. Remove the SST from the camshaft.

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

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

• If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 24.

32. Apply silicone sealant to the engine front cover upper blind plug.

33. Install the engine front cover upper blind plug.

Tightening torque:

8.0- 11.5N·m {81.6-117.2 kgf·cm, 70.9-101.7 in·lbf}

34. Install the cylinder block lower blind plug.

Tightening torque:

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

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

Tightening torque:

10.0- 14.0N·m {1.0 -1.4kgf·m, 7.4 -10.3ft·lbf}

36. Install the drive belt. (See DRIVE BELT REPLACEMENT [L3].)

37. Install the splash shield (RH).

38. Install the front wheel and tire(RH).

39. Install the cylinder head cover. (See Cylinder Head Cover Installation Note.)

40. Install the ignition coil.