Installation
Reassembly steps
1. Bracket
2. Rocker arm shaft
3. Rocker arm
4. Rocker arm spring
5. Nut; rocker arm bracket
Important Operations
1. Apply an ample amount of oil to the rocker arm and the shaft
2. Install the rocker arm and shaft.
3. The front mark must be facing up (as shown in the illustration).
The shaft front mark must be facing forward.
4. The longer end of the shaft must be on the exhaust side. The shorter end of the shaft must be on the inlet side.
Intake side shaft length: 374 mm (14.72 in.)
Exhaust side shaft length: 377 mm (14.84 in.)
Reassembly steps
1. Lower spring seat
2. Oil control
3. Valve
4. Valve spring seat
5. Upper spring seat
6. Split collar
Important Operation
1. Lower spring seat
2. Oil controller
Install the spring seat (lower) and fit the oil controller in the valve guide.
Note: Be sure to set the inner projection of the oil controller in the head groove of the valve guide.
3. Valve
Apply.engine oil to the valve stem and insert it into the valve guide.
4. Valve spring
The valve spring should be installed with blue painted end turned down.
5. Split collars
Compress the spring with the aid of valve spring compressor, then install the valve collars properly. When compressing the spring, push the valve up by hand. Valve spring compressor : J-2651 3-A
Reassembly steps
1. Cylinder head gasket
2. Cylinder head assembly
3. Cam shaft
4. Rocker arm shaft assembly
Cylinder head
Cylinder head gasket
1. Clean the upper face of the cylinder head and attach the dowels.
2. Turn the TOP mark of the cylinder head gasket upwards and attach it so as to fit the dowel.
Fig. 10 Cylinder head tightening sequence:
2. Apply engine oil to the threaded sections of the head bolts and temporarily tighten them in the order indicated in the figure, followed by tightening with predetermined torque.
Camshaft
1. Apply engine oil sufficiently to the journal of the camshaft and the journal and thrust receivers of the head. Turn the crankshaft mark upward.
Rocker arm shaft assembly
1. Apply silicon gasket beforehand to the front side of the fitting surface of No.1 rocker arm bracket with the cylinder head.
2. Apply engine oil to the lip of the camshaft oil seal and install it on the camshaft. Camshaft oil seal installer : J-33183
Fig. 11 Rocker arm tightening sequence:
3. Attach the rocker shaft spring and tighten the shaft bracket with predetermined torque. After assembly, apply lubricant to the rocker arm shafts and valves with engine oil.
Reassembly steps
1. Frontplate
2. Water pump
3. Oil pump and pulley
4. Camshaft boss
5. Camshaft timing pulley
6. Crankshaft timing pulley and guide plate
7. Tension pulley and tension spring
8. Timing belt
9. Timing belt cover
10. Crankshaft pulley bolt
Water pump
Tighten the water pump assembly with predetermined torque.
Oil Pump and Pulley
1. Apply a generous amounts of engine oil to the rotor, then install the rotor with the chamfered side turned to the cylinder body.
2. Apply engine oil to the 0-ring and insert it into the groove in the housing. Attach the rotor after applying generous amounts of engine oil.
Wrench; inner hex = 6 mm
3. Check if it turns smoothly. If not replace the cartridge assembly.
4. Attach the pulley and tighten with predetermined torque.
Camshaft Timing Pulley
Apply a detention to the pulley by putting a T-bar wrench or other proper tool over the front plate upper fitting bolt, and tighten with predetermined torque.
Crankshaft Timing Pulley and Guide Plate
Attach the guide plate and assemble with the woodruff key side of the timing pulley turned upward.
Tension Pulley and Tension Spring
Fig. 18 Timing Belt Removal:
Insert the tension pulley into stud (A), set the tension spring in plate, and temporarily tighten bolt (B) after pulling it fully to the water pump side.
Timing belt
Install the timing belt in the sequence indicated below.
(1) Bring the matchmark of the crankshaft timing pulley into agreement with that of the front oil seal retainer.
Fig. 20 Aligning camshaft timing pulley & front plate:
(2) Bring the matchmark of the camshaft timing pulley into agreement with that of the front plate. Keep the rocker arm altogether in a free state.
Note: At this point the No.4 cylinder comes to its compression, top dead center.
(3) Lay the timing belt over the crank pulley, oil pump pulley, cam pulley, and tension pulley in said order while avoiding loosening between them.
(4) Loosen bolt (B) to allow the tension spring to tighten the belt
(5) Temporarily tighten bolt (B).
(6) Temporarily attach the crank pulley.
(7) Turn the crankshaft two revolutions in the opposite direction of normal rotation to bring the crankshaft matchmark into agreement with the crankshaft timing pulley matchmark.
(8) Loosen bolt(B) and tighten the belt with the tension pulley.
(9) Tighten bolt(B) to the specified torque.
Timing Belt Cover (Upper and Lower)
Attach the timing belt cover and tighten with predetermined torque.
Crankshaft pulley bolt
Apply a detent to the crankshaft and tighten with predetermined torque.
Valve clearance adjustment
1. Bring either the No.1 or No.4 piston to top dead center on the compression stroke. Do this by turning the crankshaft to align mark on crankshaft pulley with timing mark. Hold crankshaft in above position and adjust clearance of the valves as indicated.
2. Adjust the valve clearance in the following manner using a feeler gauge.
Note: (Clear Dot) When piston in No. 1 cylinder is at TDC compression stroke.
(Dark Dot) When piston in No.4 cylinder is at TDC on compression stroke.