SB010202
Contents
1. ERVICE PS JuueTIN No SB010202 SUBJECT CHECK AND ADJUSTMENT OF VALVE CLEARANCES IN YRV IN VEHICLE SERVICING OPERATION We have received reports from some dealerships in which they said that they were unable to perform the check and adjustment of valve clearances in YRV in vehicle servicing operation Hence we will issue a manual that de scribes the details of work procedures for them Please use it as a version supplemental to Type K3 engine as re quired Furthermore we are advancing our revising of the maintenance schedule of the whole motor vehicle so that the check and adjustment of valve clearances too may further be simplified UULU DAIHATSU MOTOR CO LTD 001 DAIHATSU OVERSEAS SERVICE DIVISION L CHECK AND ADJUSTMENT OF VALVE CLEARANCE The following shows the in vehicle check and adjustment procedures for the valve clearance This informa tion has been prepared based on the Type K3 Engine Service Manuals No 9737 9232 and 9237 that have been already published Therefore for tightening torque disassembling and assembling procedures that are not mentioned please refer to these manuals 1 Removal of air cleaner The following is the removal installation procedure for the air cleaner 1 Operations prior to removal Disconnect the cable from the negative terminal of the battery NOTE e t should be noted that the memories of the diagnosis results radio etc will be erased at the same time when th2. stopper plate DA N Flat screwdriver Room mirror 5 11 12 13 14 15 16 17 6 Remove the chain from the camshaft timing sprocket 7 Remove the camshaft timing sprocket using the hexa gon section for servicing of the camshaft NOTE e The chain will interfere with the sprocket for the bolt is loosened after the chain has been removed Therefore be certain to securely hold the camshaft so that it may not turn Assemble the camshafts No 1 and No 2 For the assembling procedure refer to the section EM of the service manual described at the outset Install the cylinder head cover For the assembling procedure refer to the section EM of the service manual described at the outset Install the ignition coil and ignition coil cover For the assembling procedure refer to the section EM of the service manual described at the outset Install the chain cover service hole screw plug Perform the tightening using the hexagon wrench Width across flats 10 mm L shape approx 50 mm x 180 mm that was used during the removal Install the washer tank Tightening Torque 6 0 11 0 N m Install the air cleaner For the assembling procedure refer to page 1 Connect the cable to the negative terminal of the bat tery
3. e cable is disconnected from the negative terminal of the battery 2 Removal and installation procedures Tightening torque Non reusable parts Unit N m Charcoal canister outlet hose No 2 Air cleaner hose No 1 Charcoal canister outlet hose No 1 vs j 1 Air cleaner cap S A with air cleaner hose No 1 i 2 Air cleaner element S A 3 Vacuum hose S A Between intake manifold and pressure sensor 4 VSV for purge control with outlet hoses No 1 amp No 2 5 Air cleaner case S A 3 Main points of removal a With the air cleaner hose No 1 connected remove the air cleaner cap subassembly 0 b Disconnect the connectors of pressure sensor and intake air temperature sensor With the har nesses and hoses connected remove the VSV for purge control 4 Then remove the air clean er case subassembly 2 Ol 4 Main points of installation a Install the VSV for purge control G in such a way that the outlet hoses No 1 and No 2 may not be twisted as indicated in the figure on the right b Install the vacuum hose subassembly 3 as indi cated in the figure on the right Removal of washer tank 1 Disconnect the two harness connectors leading to the washer tank motor 2 Remove the two attaching bolts Then with the washer hose connected take out the washer tank and place it between the hood and the windshield glass NOTE e Be sure to secure
4. er the exhaust stroke Then check the valve clearance at the positions indicated in the figure on the right Valves to be checked at time when cylinder No 1 comes to top dead center under exhaust stroke Cylinder No 1 Cylinder No 2 Cylinder No 3 Cylinder No 4 If the measured value fails to conform to the specified value remove the camshafts No 1 and No 2 Then ad just the valve clearance to the specified value by replac ing the valve lifter following the procedure given below NOTE e Be sure to record the position of the valve which failed to conform to the specified value and the measurement results e For the adjustment procedure refer to the section EM of the service manual described at the outset The following shows the in vehicle removal and installation procedures for the camshafts No 1 and No 2 1 As prior operations prepare a mirror a room mirror is best fitted cloth pen light and flat screwdriver whose tio width is relatively small 2 As indicated in the illustration on the right place the room mirror on the cloth so that you can see the chain cover service hole At this time secure the pen light in such a way that it can illuminate the service hole stopper plate Room mirror Chain cover serv
5. ice hole 3 While observing the mirror apply the flat screwdriver to the hole of the stopper plate Then move it in the ar rowheaded direction and hold it in a released state Reference e Through this operation the plunger of the tensioner will be unlocked e f any difficulty is encountered in releasing the lock of the stopper plate slightly turn the stopper plate in right and left directions using the hexagon section for ser vicing of the camshaft e Since this operation must be carried out while looking into the mirror the actual operation becomes opposite to that reflected in the mirror Therefore it is necessary to get used to the operation 4 Slightly turn the camshaft to the right normal turn using the hexagon section for servicing of the camshaft until the plunger section of the tensioner be comes in a pushed state by the chain 5 While holding the condition in Step 4 remove the flat screwdriver from the chain cover service hole Then insert a hexagon wrench with the hole of the stopper plate aligned with that of the tensioner Tool Hexagon wrench Width Across Flats 2 5 mm NOTE e The camshaft must be held using the hexagon section for servicing e Be sure to secure the hexagon wrench by means of a tape etc so that it may not be pulled out Reference e Through this operation the plunger of the tensioner will be held in a pushed state Hone Te Chain cover service hole
6. the washer tank by means of tapes etc so that it may not fall down Remove the chain cover service hole screw plug using a hexagon wrench NOTE e It is recommended to use an L shaped hexagon wrench with a width across flats of 10 mm Approx 50 mm x 180 mm Remove the ignition coil cover and ignition coil Remove the cylinder head cover Turn the crankshaft in the normal direction until the timing mark V notch of the crankshaft pulley is aligned with the indicator mark of the timing chain cover The cylinder No 1 comes to the top dead center Ensure that the mating marks of the camshaft timing sprocket face upward In cases where the mating marks are not facing upward turn the crankshaft one more turn Then ensure that the mating marks are facing upward The cylinder No 1 comes to the top dead center under the compression stroke A Z Charcoal canister N outlet hose No 1 NO eo outlet hose No 2 l Charcoal canister Va ff amp hexagon wrench TEZ VAN ae aie ating marks 7T Y 3 8 10 Check the valve clearance at the positions indicated in the figure on the right using a thickness gauge Valves to be checked at time when cylinder No 1 comes to top dead center under compression stroke Cylinder No 1 Cylinder No 2 Cylinder No 3 Cylinder No 4 Turn the crankshaft once so that the cylinder No 1 comes to the top dead center und
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