AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY (WITH ROCKER COVERS REMOVED)
If the engine was overhauled or previously disassembled (i.e. intake manifold and/or cylinder head were removed), follow the steps below.
Scheme 241
Scheme 242
Scheme 243
Scheme 244
Scheme 245
Scheme 246
- Loosen rocker shaft bolts to relieve belt tension caused by the camshafts.
- Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench.
- Turn tensioner 70 to 80 degrees clockwise with hexagon wrench to release belt tension, and temporarily tighten lock nut.
- Turn crankshaft clockwise at least two times, then slowly set No. 1 piston at TDC on its compression stroke.
- Push middle of timing belt between RH camshaft sprocket and tensioner pulley with force of 98 N (10 kg, 22 lb) to apply tensions on part A and part B.
- Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench.
- Set feeler gauge as shown in figure which is 0.5 mm (0.0206 in) thick and 12.7 mm (0.500 in) wide.
- Turn crankshaft clockwise until feeler gauge is positioned as shown in figure. Timing belt will move about 2.5 teeth.
- Tighten tensioner lock nut, keeping tensioner steady with hexagon wrench.
- Turn crankshaft clockwise or counterclockwise, and remove feeler gauge.
- Turn crankshaft clockwise at least two times, then slowly set No. 1 piston at TDC on its compression stroke.
- Measure deflection of timing belt midway between camshaft pulleys while pushing with 98 N (10 kg, 22 lb) force. Belt deflection when engine is cold (Reference value): 13 - 15 mm (0.51 - 0.59 in)/98 N (10 kg, 22 lb)
- If belt deflection is not within specification, return to step 1 and repeat procedure.
- Install lower and upper belt covers.
- Install the remaining components in the reverse order of removal.
Scheme 247
Scheme 248
- Remove rocker cover.
- Remove rocker shaft assembly and valve lifters with valve lifter guide.
- Remove valve springs and valve oil seal. Piston concerned should be set at TDC to prevent valve from falling. When removing intake side valve oil seal, use Tool or suitable tool. When removing exhaust side valve oil seal, pull it out with suitable tool.
- Apply engine oil to new valve oil seal and install it.
Scheme 249
- Before installing valve oil seal, install inner valve spring seat.
- When installing intake side valve oil seal, use Tool.
- When installing exhaust side valve oil seal, set it by hand.
Disassembly
| CAUTION | When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts. If hydraulic valve lifter is kept on its side, there is a risk of air entering it. After removal, always set hydraulic valve lifter straight up, or when laying it on its side, have it soak in new engine oil. Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up. |
Scheme 250
Scheme 251
Scheme 252
Scheme 253
- Remove exhaust manifolds from cylinder head.
- Remove rocker shafts with rocker arms. Bolts should be loosened in two or three steps .
- Remove hydraulic valve lifters and lifter guide. Hold hydraulic valve lifters with wire so that they will not drop from lifter guide .
- Remove oil seal and camshaft. Before removing camshaft, measure camshaft end play .
- Remove valve components with Tool.
- Remove valve oil seals with Tool or suitable tool.