Rocker Arm Assembly: Service and Repair

Fig. 14 Camshaft rear cover & thrust case bolt removal. 1400cc engine:

REMOVAL

1. Disconnect breather hose from air cleaner and rocker arm cover, then remove air cleaner.
2. Remove timing belt cover, position belt tensioner toward water pump as far as possible and secure in this position, then remove timing belt and camshaft sprocket as outlined in ``Cylinder Head, Replace.'' Do not rotate crankshaft after removing camshaft sprocket.
3. Remove rocker arm cover.
4. Remove rocker arm shaft attaching bolts, then lift rocker shaft and arms as an assembly from cylinder head.
5. Remove rocker shaft bolts, rocker arms and springs from rocker shaft.
6. Remove rear cover from cylinder head, then remove camshaft thrust case retaining bolt and remove camshaft and thrust case from transaxle side of cylinder head, Fig. 14.

Fig. 15 Camshaft endplay check. 1400cc engine:

INSTALLATION

1. Install camshaft thrust case and thrust plate on end of camshaft, then install and tighten bolt. Check camshaft endplay using a feeler gauge, Fig. 15. Endplay should be 0.002 - 0.008 inch. If endplay exceeds limits, replace thrust case and recheck endplay. If clearance still exceeds limits, check rear camshaft journal for wear and replace camshaft, if necessary.

Fig. 14 Camshaft rear cover & thrust case bolt removal. 1400cc engine:

2. Lubricate bearing surfaces and thrust surfaces of camshaft with engine oil, then install camshaft from transaxle side of cylinder head. When installing camshaft, position thrust case so bolt hole is aligned with bolt hole in cylinder head, then install and tighten thrust case retaining bolt, Fig. 14.
3. Install timing belt under cover, ensure camshaft dowel pin hole is pointing up (TDC on compression stroke for No. 1 cylinder), then install camshaft sprocket and timing belt.
4. Release timing belt tensioner and ensure timing marks are properly aligned as outlined in ``Timing Belt, Replace.''

Fig. 16 Rocker arm & shaft assembly & installation. 1400cc engine:

5. Install rocker arms and springs on rocker shaft, Fig. 16. Intake rocker arms have two adjusting screws, one for valve adjustment and the other for jet valve adjustment. Both intake and exhaust rocker have identification marks stamped on the side of the rocker arm at the valve end. Rocker arms marked 1-3 can be installed at cylinder locations 1 and 3. Rocker arms marked 2-4 can be installed at cylinder locations 2 and 4. Also note that rocker arm springs for exhaust rocker arms have a free length of 1.85 inch, while those for intake rocker arms have a free length of 3.03 inch.
6. Back-off rocker arm adjusting screws, install rocker arm and shaft assembly, and torque mounting bolts to 15-19 ft. lbs.
7. Align camshaft sprocket and crankshaft sprocket timing marks, referring to ``Valves, Adjust'' procedure. Set valve to a cold setting of .003 inch for intake and jet valves and .007 inch for exhaust valves.
8. Temporarily install rocker cover and gasket.
9. Start engine and allow to reach operating temperature. Adjust valves to warm clearance listed in ``Valve Specifications Chart'' as described under ``Valves, Adjust.''
10. Install rocker arm covers, then install timing belt cover.