Disconnect the negative cable from the battery.
Remove the front wheel and tire (right).
Remove the air filter assembly.
Remove the ignition coils.
Disconnect the ventilation hose.
Remove the cylinder head cover.
Remove the drive belt.
Fig. 2.237. Removing the front engine cover plug: 1 – plugs
Remove the front engine cover plug shown in Figure 2.237.
Fig. 2.238. Installing a bolt into a process hole
Screw the bolt in manually (M10x1.25, length 25mm or more) into the technological hole on the right side, as shown in Figure 2.238, until it rests against the tensioner lever.
Fig. 2.239. Weakening the tension of the timing chain
Loosen the timing chain tension (fig. 2.239).
Press the chain tensioner connector plate through the access hole on the left side using a thin flat-head screwdriver (precision screwdriver).
Fig. 2.240. Rotation of the crankshaft pulley
After this, with the plunger stopper released, rotate the crankshaft pulley back (counterclockwise) (fig. 2.240).
Fig. 2.241. Moving the tensioner lever
After loosening the timing chain tension, simultaneously move the tensioner lever to the position shown in Figure 2.241.
Note: The timing chain pushes the tensioner lever down as the crankshaft pulley rotates backwards (counterclockwise).
Tighten the bolt (M10x1.25) installed in the front cover until it hits the inner part of the rib on the tensioner lever.
Fig. 2.242. Fixing the tensioner lever with the installed bolt
Caution! Secure the tensioner lever with the installed bolt, tighten the bolt six to seven turns until it reaches the position shown in Figure 2.242.
Fig. 2.243. Fixing the camshaft from turning
Secure the camshaft from turning by holding it with a wrench by the hexagon (fig. 2.243).
Loosen the camshaft sprocket mounting bolt.
Fig. 2.244. Removing the camshaft drive sprocket from the intake side
Remove the camshaft drive sprocket from the exhaust side with the timing chain retracted (fig. 2.244).
Fig. 2.245. Procedure for loosening the camshaft bearing cover mounting bolts
Loosen the camshaft bearing cover mounting bolts in 2–3 passes in the order shown in Figure 2.245.
Remove the camshaft bearing caps.
Remove the intake and exhaust camshafts.
Remove the valve lifters.
Select the appropriate valve lifter according to the valve clearance check results and install it.
Valve tappet to be selected: thickness of removed valve tappet + measured valve clearance – standard valve clearance (0.3 mm).
Standard valve clearance (on a cold engine): 0.27–0.33 mm.
Fig. 2.246. Alignment of timing marks on the crankshaft pulley and front engine cover
Align the timing marks on the crankshaft pulley and the engine front cover, and then set the piston of cylinder No.1 to the TDC position (fig. 2.246).
Install the intake and exhaust camshafts, with the piston of cylinder No.1 near the TDC position of the compression stroke.
Fig. 2.247. Positions of camshaft bearing caps
Install the camshaft bearing caps in the positions shown in Figure 2.247 and temporarily tighten camshaft mounting bolts No.1 and No.7.
Fig. 2.248. Camshaft mounting bolt tightening sequence
Tighten the camshaft mounting bolts evenly in 2–3 passes in the order shown in Figure 2.248.
Tightening torque: 11.3–14.2 Nm.
Fig. 2.249. Alignment of timing marks on camshafts along the upper horizontal surface of the cylinder head
Align the timing marks on the intake and exhaust camshafts so that they form a straight line when aligned with the top horizontal surface of the cylinder head (fig. 2.249).
Secure the camshaft from turning by holding it with a wrench by the hexagon.
Tighten the camshaft sprocket mounting bolt.
Tightening torque: 6–60.8 Nm.
Remove the bolt (M10x1.25) holding the tensioner lever.
Make sure that the timing chain has no slack, and then check that the marks on the camshaft sprocket and crankshaft pulley match up.
Check the valve opening and closing timing by turning the crankshaft clockwise two turns.
Fig. 2.250. Places of sealant application
(Based on website data: MAZBOOK.ru)
Apply silicone sealant to the plug as shown in Figure 2.250.
Install the front engine cover plug.
Tightening torque: 3.0–5.0 Nm.
Install the drive belt.
Install the cylinder head cover.
Connect the ventilation hose.
Install the ignition coils.
Install the air filter assembly.
Install the front wheel (right).