CAMSHAFT VALVE CLEARANCE
EM-21
< ON-VEHICLE MAINTENANCE >
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c. Rotate crankshaft pulley (2) one revolution (360 degrees) and
align TDC mark (without paint mark) (A) to timing indicator (1) on
front cover.
• Measure the valve clearance at locations marked “ ×” as shown
in the table below [locations indicated with black arrow ( ) as
shown] with a feeler gauge.
3. If out of standard, perform adjustment procedure.
ADJUSTMENT • Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-58, " Exploded View " .
2. Remove valve lifters at the loca tions that are out of the standard.
3. Measure the center thickness of the removed valve lifters with a micrometer (A).
4. Use the equation below to calculate valve lifter thickness for replacement. B : White paint mark (Not use for service) PBIC3673E
A : No. 4 cylinder compression TDC
: Engine front
Measuring position No. 1 CYL. No . 2 CYL. No. 3 CYL. No. 4 CYL.
Measurement
point EXH
× ×
INT × × PBIC3708E
PBIC3195J
Valve lifter thickness calculation: t = t
1 + (C 1– C 2)
t = Valve lifter thickness to be replaced
t 1
= Removed valve lifter thickness
C 1
= Measured valve clearance
C 2
= Standard valve clearance:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)
EM-50< ON-VEHICLE REPAIR >
[HR16DE]
TIMING CHAIN
4. Remove the following parts. • Intake manifold: Refer to EM-28, " Exploded View " .
• Drive belt: Refer to EM-15, " Removal and Installation " .
• Water pump pulley: Refer to CO-20, " Exploded View " .
• Ground cable (RH)
5. Support the bottom surface of engine using a tr ansmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-88, " Exploded View " .
6. Remove rocker cover. Refer to EM-46, " Exploded View " .
7. Set No. 1 cylinder at TDC of its compression stroke with the following procedure:
a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
b. Make sure the matching marks on each camshaft sprocket are positioned as shown.
• If not, rotate crankshaft pulley one more turn to align matching marks to the positions.
8. Remove crankshaft pulley with the following procedure:
a. Secure crankshaft pulley (1) using a suitable tool (A).
b. Loosen and pull out crankshaft pulley bolts. CAUTION:
Never remove the bolts as they are used as a supporting
point for the pulley puller.
c. Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley. B : White paint mark (Not use for service) PBIC3673E
1 : Camshaft sprocket (EXH)
2 : Camshaft sprocket (INT)
A : Matching mark (stamp)
B : Matching mark (peripheral stamp line) PBIC3872E
PBIC3710E
B : M6 bolt
Tool number : KV11103000 ( — ) PBIC3711E
CAMSHAFT
EM-59
< ON-VEHICLE REPAIR >
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5. Support the bottom surface of engine using a trans
mission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-88, " Exploded View " .
6. Remove rocker cover. Refer to EM-46, " Exploded View " .
7. Set No. 1 cylinder at TDC of its comp ression stroke with the following procedure:
a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
b. Make sure the matching marks on each camshaft sprocket are positioned as shown.
• If not, rotate crankshaft pulley one more turn to align matching marks to the positions.
8. Remove crankshaft pulley with the following procedure:
a. Secure crankshaft pulley (1) using a suitable tool (A).
b. Loosen and pull out crankshaft pulley bolts. CAUTION:
Never remove the bolts as they are used as a supporting
point for the pulley puller.
c. Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley.
9. Remove front cover with the following procedure: B : White paint mark (Not use for service) PBIC3673E
1 : Camshaft sprocket (EXH)
2 : Camshaft sprocket (INT)
A : Matching mark (stamp)
B : Matching mark (peripheral stamp line) PBIC3872E
PBIC3710E
B : M6 bolt
Tool number : KV11103000 ( — ) PBIC3711E
DRIVE BELTS
EM-137
< SERVICE INFORMATION >
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1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a box wrench securely. Then move the wrench handle in the
direction of arrow (loosening direction of tensioner).
WARNING:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.
2. Insert a rod such as short-length screwdriver approximately 6 mm (0.24 in) in diameter into the hole (B) of retaining boss to fix
drive belt auto-tensioner.
3. Install drive belt. 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.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-136, " Checking Drive Belts " .
Component INFOID:0000000004307127
Removal and Installation of Drive Belt Auto Tensioner INFOID:0000000004307128
REMOVAL 1. Remove drive belt. Refer to EM-136, " Removal and Installation " .
2. Release the fixed drive belt auto-tensioner pulley.
3. Loosen bolt and remove drive belt auto-tensioner. NOTE: PBIC3936E
1. Front cover 2. Drive belt auto–tensioner 3. Idler pulley (models without A/C)
4. Bracket (models without A/C) 5. Shaft (models without A/C) PBIC4698E
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Removal and Installation
INFOID:0000000004307143
CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
REMOVAL 1. Remove front RH wheel. Refer to WT-7, " Rotation " .
2. Remove front fender protector (RH). Refer to EI-24, " Removal and Installation " .
3. Drain engine oil. Refer to LU-17, " Changing Engine Oil " .
CAUTION:
Perform this step when engine is cold.
4. Remove the following parts. • Rocker cover: Refer to EM-153, " Component " .
• Drive belt: Refer to EM-136, " Removal and Installation " .
• Water pump pulley: Refer to CO-43, " Component " .
• Ground cable (between engine bracket (RH) and radiator core support)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH). Refer to EM-195, " Component " .
6. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.
b. At the same time, make sure that the cam noses of the No.1 cyl- inder are located ( ) as shown.
• If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
7. Hold crankshaft pulley (1) using suitable tool (A) loosen crank- shaft pulley bolt, and locate bolt seating surface at 10 mm (0.39
in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as it will be used as
a supporting point for the pulley puller.
16. Oil pump drive chain 17. Camshaft sprocket (INT) 18. Timing chain tension guide
19. O-ring 20. Chain tensioner (for oil pump)
A. Refer to EM-161 B. Refer to
EM-170 C : White paint mark (Not use for service)
CAMSHAFT
EM-173
< SERVICE INFORMATION >
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• Measure the inner diameter of camshaft bracket with a bore gauge
(A).
CAMSHAFT JOURNAL OIL CLEARANCE
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
• If it exceeds the limit, replace camshaft or cylinder head, or both. NOTE:
Camshaft bracket cannot be replaced as a single part , because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play 1. Install camshaft in cylinder head.
2. Install dial indicator in thrust direction on front end of camshaft. Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis).
• Measure the following parts if out of the standard.
- Dimension (A) for groove of cylinder head No. 1 journal
- Dimension (B) for camshaft flange
• Apply the standards above, and then replace camshaft and/or cylinder head, if necessary.
Camshaft Sprocket Runout 1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION:
Never support No. 1 journal (on the side of cam shaft sprocket) because it has a different diameter
from the other four locations. B : Measuring direction of inner diameter
Standard: No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5 : 25.000 - 25.021 mm (0.9843 - 0.9851 in) PBIC3180J
Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4, 5 : 0.030 - 0.071 mm (0.0012 - 0.0028 in)
Limit:
: 0.15 mm (0.0059 in)
Standard : 0.075 - 0.153 mm (0.0030 - 0.0060 in)
Limit : 0.24 mm (0.0094 in) PBIC3181J
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in) PBIC3183J
EM-174< SERVICE INFORMATION >
[MR18DE]
CAMSHAFT
2. Measure the camshaft sprocket runout with a dial indicator (A). (Total indicator reading)
• If it exceeds the limit, replace camshaft sprocket.
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-178," Valve Clearance " .
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer (A).
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A).
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
• If out of the standard, referring to the each standard of va lve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSTALLATION
1. Install valve lifters. • Install them in the original positions.
2. Install camshafts. Limit : 0.15 mm (0.0059 in)
PBIC3182J
KBIA0182E
Standard:
Intake : 33.977 - 33.987 mm (1.3377 - 1.3381 in)
Exhaust : 29.977 - 29.987 mm (1.1802 - 1.1806 in) PBIC3185J
Standard:
Intake : 34.000 - 34.021 mm (1.3386 - 1.3394 in)
Exhaust : 30.000 - 30.021 mm (1.1811 - 1.1819 in)
Standard: 0.013 - 0.044 mm (0.0005 - 0.0017 in) PBIC3184J
EM-180< SERVICE INFORMATION >
[MR18DE]
CAMSHAFT
• Rotate crankshaft pulley (1) one revolution (360 degrees) and align TDC mark (no paint) (B) to timing indicator (A) on front
cover.
• By referring to the figure, measure the valve clearance at loca- tions marked × as shown in the table below [locations indi-
cated with black arrow ( )] with a feeler gauge.
• No. 4 cylinder compression TDC
3. If out of standard, perform adjustment.
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-170, " Removal and Installation " .
2. Remove valve lifters at the locations that are out of the standard.
3. Measure the center thickness of the removed valve lifters with a micrometer (A).
4. Use the equation below to calculate valve lifter thickness for replacement. C : White paint mark (Not use for service) PBIC3960E
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
No. 4 cylinder at
compression TDC EXH
× ×
INT × ×
A : Exhaust side
B : No.1 cylinder
C : No.2 cylinder
D : No.3 cylinder
E : No.4 cylinder
F : Intake side
: Engine front PBIC3194J
PBIC3195J
Valve lifter thickness calculation: t = t
1 + (C 1 – C 2)
t = Valve lifter thickness to be replaced
t 1
= Removed valve lifter thickness
C 1
= Measured valve clearance
C 2
= Standard valve clearance: