Valve Rocker Assembly

REMOVAL
1. Remove the V-belt.
2. Remove the crankshaft pulley.
3. Remove the belt cover.
4. Remove the timing belt assembly.
5. Remove the camshaft sprocket.
6. Disconnect the PCV hose and remove the rocker cover.
7. Removal of valve rocker assembly:





a. Remove the bolts (a) through (h) in alphabetical sequence.

CAUTION: Leave two or three threads of bolts (g and h) engaged to retain the valve rocker assembly.





b. Remove the valve rocker assembly.

INSTALLATION
1. Installation of valve rocker assembly:





a. Temporarily tighten the bolts (a) through (d) equally as shown in figure.

CAUTION: Do not allow the valve rocker assembly to gouge knock pins.

b. Tighten the bolts (e) through (h) to specified torque.
c. Tighten the bolts (a) through (d) to specified torque.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
2. Adjust the valve clearances.
3. Install the rocker cover and connect PCV hose.
4. Install the camshaft sprocket.
5. Install the timing belt assembly.
6. Install the belt cover.
7. Install the crankshaft pulley.
8. Install the V-belt.

DISASSEMBLY
1. Remove the bolts which secure the rocker shaft.
2. Extract the rocker shaft. Remove the valve rocker arms, springs and shaft supports from rocker shaft.

CAUTION: Arrange all removed parts in order so that they can be installed in their original positions.

3. Remove the nut and adjuster screw from valve rocker.

ASSEMBLY
1. Install the adjuster screw and nut to valve rocker.
2. Arrange the valve rocker arms, springs and shaft supports in assembly order and insert the valve rocker shaft.
Tightening torque (Shaft supports installing bolts): 5 Nm (0.5 kgf-m, 3.6 ft. lbs.)

CAUTION: Valve rocker arms, rocker shaft and shaft supports have identification marks. Ensure the parts with same markings are properly assembled.

3. Install the valve rocker shaft securing bolts.

INSPECTION
1. VALVE ROCKER ARM





1 of 2





2 of 2

a. Measure the inside diameter of valve rocker arm and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).
Clearance between arm and shaft:
Standard: 0.020 - 0.054 mm (0.0008 - 0.0021 inch)
Limit: 0.10 mm (0.0039 inch)
b. If the oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows greater amount of wear.
Rocker arm inside diameter: 22.020 - 22.041 mm (0.8669 - 0.8678 inch)
Rocker shaft diameter: 21.987 - 22.000 mm (0.8656 - 0.8661 inch)
c. Measure the inside diameter of rocker shaft support and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).
Clearance between support and shaft:
Standard: 0.005 - 0.039 mm (0.0002 - 0.0015 inch)
Limit: 0.05 mm (0.0020 inch)
d. If the oil clearance exceeds the limit, replace the rocker shaft support or shaft, whichever shows greater amount of wear.
Rocker shaft support inside diameter: 22.005 - 22.026 mm (0.8663 - 0.8672 inch)
Rocker shaft diameter: 21.987 - 22.000 mm (0.8656 - 0.8661 inch)
e. If the cam or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker arm.
f. Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker arm.

2. INTAKE AND EXHAUST VALVE ROCKER SHAFT
Visually check the oil relief valve of shaft end for any of the following abnormalities:
^ Breaks in check ball body
^ Foreign particles caught in valve spring
^ Oil leakage at check ball

CAUTION: Repair or replace the valve rocker shaft as necessary.