Tension Adjustment
Refer to: " DRIVE BELT ".
Scheme 9
- Remove front wheel and tire (RH).
- Remove front fender protector (RH). Refer to " «EXPLODED VIEW»(ref-295102-S41180941832008081400000) ".
- Hold the hexagonal part in center of drive belt auto-tensioner pulley with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner). CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. Never loosen the hexagonal part in center of drive belt auto-tensioner pulley (Never turn it counterclockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
- Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screwdriver into the hole of the retaining boss to fix drive belt auto-tensioner pulley.
- Loosen drive belt from water pump pulley in sequence, and remove it.
Scheme 10
- Hold the hexagonal part in center of drive belt auto-tensioner pulley with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner). CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. Never loosen the hexagonal part in center of drive belt auto-tensioner pulley (Never not turn it counterclockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
- Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screwdriver into the hole of retaining boss to fix drive belt auto-tensioner pulley.
- Hook drive belt onto all pulleys except for water pump, and then onto water pump pulley finally. CAUTION: Confirm drive belt is completely set to pulleys. Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each pulley groove.
- Release drive belt auto-tensioner, and apply tension to drive belt.
- Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
- Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to " «EXPLODED VIEW»(ref-295108-S21073347162008081400000) ".
Scheme 11
Scheme 12
- Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B).
- Pull up the air cleaner cover forward (C) and remove it.
- Remove the air cleaner filter (1) and holder (2) assembly from the air cleaner case.
- Remove the air cleaner filter from the holder.
ADJUSTMENT
- Perform adjustment depending on selected head thickness of valve lifter.
Scheme 13
Scheme 14
- Remove camshaft. Refer to " «EXPLODED VIEW»(ref-295108-S04945981832008081400000) ".
- Remove valve lifters at the locations that are out of the standard.
- Measure the center thickness of the removed valve lifters with a micrometer (A).
- Use the equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: t = t1 + (C1 - C2) t = Valve lifter thickness to be replaced t1 = Removed valve lifter thickness C1 = Measured valve clearance C2 = Standard valve clearance: Intake : 0.28 mm (0.011 in) Exhaust : 0.30 mm (0.012 in) Thickness of new valve lifter (B) can be identified by stamp mark (A) on the reverse side (inside the cylinder). Stamp mark "788" indicates 7.88 mm (0.3102 in) in thickness. NOTE: Available thickness of valve lifter: 26 sizes range 7.88 to 8.38 mm (0.3102 to 0.3299 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".
- Install the selected valve lifter.
- Install camshaft. Refer to " «EXPLODED VIEW»(ref-295108-S04945981832008081400000) ".
- Manually rotate crankshaft pulley a few rotations.
- Check that valve clearances for cold engine are within specifications by referring to the specified values. Refer to " «INSPECTION»(ref-295108-S07348329282008081400000) ".
- Install all removed parts in the reverse order of removal.
- Warm up the engine, and check for unusual noise and vibration.
Scheme 15
Scheme 16
- Warm up engine thoroughly. Then, stop it.
- Release fuel pressure. Refer to " «INSPECTION»(ref-295105-S04323263622008081400000) ".
- Disconnect fuel pump fuse to avoid fuel injection during measurement. Refer to " «DESCRIPTION»(ref-295105-S18691081832008081400000) ".
- Remove ignition coil and spark plug from each cylinder. Refer to " «EXPLODED VIEW»(ref-295108-S01690322732008081400000) ".
- Connect engine tachometer (not required in use of CONSULT-III).
- Install compression tester with adapter onto spark plug hole. Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.
- With accelerator pedal fully depressed, turn ignition switch to "START" for cranking. When the gauge pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cylinder. Compression pressure : Refer to " «GENERAL SPECIFICATION»(ref-295108-S38838161582008081400000) ". CAUTION: Always use a fully changed battery to obtain specified engine speed. If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure the compression pressure again. If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. If the added engine oil improves the compression, piston rings may be worn out or damaged. Check piston rings and replace if necessary. If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly. If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, gaskets are leaking. In such a case, replace cylinder head gaskets.
- After inspection is completed, install removed parts.
- Start engine, and confirm that engine runs smoothly.
- Perform trouble diagnosis. If DTC appears, erase it. Refer to " «DESCRIPTION»(ref-295105-S22816121802008081400000) ".