If your Daihatsu Feroza / Daihatsu Rocky / Daihatsu Sportrak valves aren't adjusted properly you can suffer from one of two things. (1) The valves are too tight and it will cause them to wear (or burn out) quicker or (2) The valves are too loose and you will experience a loss of power. According to the service manual you should check your valves every 15,000 mi. or every 18 months, which ever comes first.
| The measurement and adjustment of valve clearances are carried out when each of the pistons of the No. 1 and No. 4 cylinders is set to the top dead center at the end of the compression stroke. | |
NOTE: - The valve clearace adjustment is performed normally when the engine is in a hot condition.
- "Hot engine condition" denotes a condition in which the cooling water temperature is 75-85 deg. C (167 - 185 deg F) and the engine oil temperature is above 65 deg C (149 deg F).
- However, when the engine has been overhauled, it is necessary to adjust the valve clearances while the engine is cold and to readjust the valve clearances in a hot condition after warming up the engine.
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(1) Removal of air chamber - Disconnect the air hoses from the air chamber.
- Detach the air chamber by removing the three attaching bolts.
- Unlock the two clamps with your hand. Then remove the air chamber.
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(2) Removal cylinder head cover - Disconnect the accelerator cable from the clamp.
- Detach the spark plug wires from the clamps.
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- Detach the spark plug wires at the cylinder head.
NOTE: - Be sure to hold the rubber boot during the spark plug wire disconnection. Never remove the spark plug wire, holding the cord portion.
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- Detach the air chamber bracket and accelerator cable clamp by removing two screws. (If the radio equipped vehicle, remove the bond cable from the air chamber bracket.)
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- Disconnect the PCV hoses from the cylinder head cover.
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- Loosen the nine bolts (10 mm) over two to three stages in the sequence shown in the right figure. After removing the bolks, proceed to remove the sylinder head cover.
NOTE: - Be sure to loosen the bolts progressively and uniformly over two or three stages.
- The timing belt cover attaching bolt (1) should be pulled out fully.
- Be very careful not to damage the grommets of the spark plug tubes.
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(3) Inspection and adjustment of valve clearances - Turn the crankshaft until the recessed mark on the crankshaft pully is aligned with the indicator mark on the timing belt cover.
NOTE: - If the vehicles equipped with the power steering and the air-conditioner or only the power steering is equipped, turn the power steering pump pully while pushing the drive belt.
- If the vehicles equipped with only the air conditioner, remove the engine under cover, rubber plate, engine under cover No. 3 and the lower fan shroud. Then turn the crankshaft pully from the vehicle lower side.
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- Check to see if the valve rocker arms of the No. 1 cylinder are free or are being pushed up. According to the following table, check and/or adjust the valve clearances, using a thickness gauge.
Valve clearances (Hot condition)
Intake: 0.20 - 0.30 mm (0.008 - 0.012 inch)
Exhaust: 0.28 - 0.38 mm (0.011 - 0.015 inch)
(Reference: Cold)
Intake: 0.18 mm (0.007 inch)
Exhaust: 0.25 mm (0.010 inch) NOTE: - Before the adjusting bolts are tightened, apply engine oil to the lock nuts and rocker arm adjusting bolts.
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| The "O" marks denote those valves that can be adjusted under that setting. |
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- Turn the crankshaft 360 degrees. Proceed to check and/or adjust the remaining valve clearances.
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(4) Installation of cylinder head cover - Wipe off the oil or dirt from the gasket surface of the cylinder head cover.
CAUTION: - Be sure not to drop the dirt or gasket tips into the timing belt cover.
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- Check the cylinder head cover gasket for evidence of damage. Replace the gasket, as required.
NOTE: - Install the cylinder head cover gasket in such a direction that the identification mark may come at the intake side.
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- Check the rubber grommets of the spark plug tubes for evidence of damage. Replace the rubber grommets, as required. (See page EM-73.)
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- Install the cylinder head cover gasket on the cylinder head. Apply the Three Bond 1104 to the four points on the cylinder head, as indicated int he figure.
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- Install the cylinder head cover on the cylinder head.
NOTE: - Be very careful not to damage the rubber grommets for spark plugs during the cover installation.
- Make sure that the rubber grommet is fitted properly to the spark plug tube.
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- Tighten the cylinder head cover bolts over two or three stages in the sequence shown in the right figure, until they are tightened to the specified torque.
Tightening Torque: 0.3 - 0.5 kg-m (2.2 - 3.6 ft-lb, 3.0 - 4.9 N.m) |  |
- Tighten the timing belt cover attaching bolt.
Tightening Torque: 0.2 - 0.4 kg-m (1.4 - 2.9 ft-lb, 2.0 - 3.9 N.m) |  |
- Tighten the air chamber bracket tightening bolks and clamp bolt. Then clamp the accelerator cable.
Tightening Torque: 0.3 - 0.5 kg-m (2.2 - 3.6 ft-lb, 3.0 - 4.9 N.m) - Connect the bond cable to the air chamber bracket, and tighten the attaching bolt. (Only for the radio equipped vehicle)
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- Connect the PCV hoses to the cylinder head cover.
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- Install the spark plug wires to the spark plugs.
NOTE: - Be sure that the spark plug wire is connected securely to each spark plug.
- Care should be exercised not to damage the spark plug wire rubber grommet with the spark plug tube.
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- Install the spark plug wires to clamps.
NOTE: - Align the pink paint marks provided on the No. 1 and No. 2 spark plug wires with clamping position indicated in the right figure.
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(5) Installation of intake air chamber - Connect the air hoses to the intake air chamber.
NOTE: - At this time, make sure that the mating mark at the host side is aligned with the mating mark at the intake air chamber side.
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- Install the clamps of teh intake air chamber hoses.
- Connect the air hoses of the air conditioner and power steering.
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- Install the intake air chamber to the bracket with three bolts.
(6) Start the engine. Ensure that the engine exhibits no trouble, such as oil leakage. |  |
