Timing Chain: Service and Repair

TIMING CHAIN REMOVAL/INSTALLATION [L3]

Warning
- Hot engines and oil can cause severe burns. Be careful not to burn yourself during removal/ installation of each component.
- Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION [L3].) Service Precautions

1. Disconnect the negative battery cable.
2. Remove the following parts.
1) Plug hole plate
2) Ignition coils
3) Drive belt
4) Under cover and splash shields (RH)
5) Front wheel and tire (RH)
6) Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way.
7) Crankshaft position (CKP) sensor
8) A/C compressor with the oil hose still connected and position the A/C compressor so that it is out of the way
9) Coolant reserve tank with the hose still connected and position the coolant reserve tank so that it is out of the way

3. Remove the bracket installation nut shown in the figure, then set the bracket and electric power steering oil pump hose away from the vehicle.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Start the engine. And inspect and adjust the following:
- Leakage of engine oil. (See ENGINE OIL LEVEL INSPECTION [L3].) Testing and Inspection
- Runout and contact of pulley and belt.
- Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [L3].) Testing and Inspection

Crankshaft Pulley Lock Bolt Removal Note

1. Remove the cylinder block lower blind plug.

2. Install the SST.
3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST).

4. Hold the crankshaft pulley using the SSTs.

No.3 Engine Mount Rubber Removal Note
1. Remove the following parts to install SST.
1) Battery duct.
2) Air cleaner assembly.
3) Windshield wiper arm and blade.
4) Cowl grille.
5) Cowl panel.
6) No.1 reserve tank with the hose still connected and position the No.1 reserve tank aside so that it is out of the way.
7) Reserve tank bracket.
2. Install the SST using the following procedure.

Caution
- Refer to the SST instruction manual for the basic handing procedure.

1) As shown in the figure, set the rear shafts of the SST to the left and right shock absorber bolts.
2) Install the left rear shaft of the SST to the bolt of the left shock absorber. (identical position to the right side)

3) Install front foot No.2 to the left/right front shaft of the SST, then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure.
4) Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.
5) Make sure each joint is securely tightened.

3. Suspend the engine using the SST.

Front Oil Seal Removal Note

1. Remove the oil seal using a screwdriver as shown.

Chain Tensioner Removal Note
1. Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool.
2. Slowly compress the tensioner piston.

3. Hold the tensioner piston using a 1.5 mm (0.059 in) wire or paper clip.

Oil Pump Sprocket Removal/Installation Note

1. Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the oil pump against rotation as shown in figure.
2. Remove/install the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Tightening torque
20-30 N-m (2.1-3.0 kgf-m, 14.8-22.1 ft-lbf)

Timing Chain Installation Note

1. Install the SST to the camshaft as shown in the figure.
2. Install the timing chain.
3. Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain.

Engine Front Cover Installation Note

Caution
- Install the engine front cover within 10 min of applying the silicone sealant.

1. Apply silicone sealant to the engine front cover as shown.

Thickness
A: 2.2-3.2 mm (0.09-0.12 in)
B: 1.5-2.5 mm (0.06-0.09 in)

2. Install the engine front cover bolts in the order shown in the figure.

Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.

3. Compress the oil seal using the SST and a hammer.

Front oil seal press-in amount 0-0.5 mm (0-0.019 in)

No.3 Engine Mount Installation Note

Note
- If the No.3 engine mount bracket and the engine are removed, retighten the No.3 engine mount stud bolts.

1. Tighten the No.3 engine mount stud bolts.

Tightening torque
7.0-13.0 N-m (71.4-132.5 kgf-cm, 62-115 in-lbf)

2. Install the No.3 engine mount rubber hand-tighten.

3. Tighten the No.3 engine mount bracket bolts and nuts in the order as shown in the figure.

Tightening torque
74.5-104.9 N-m (7.6-10.6 kgf-m, 55-77 ft-lbf)

Crankshaft Pulley Lock Bolt Installation Note

1. Install the SST to the camshaft as shown in the figure.
2. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST.)

3. To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0), fix the crankshaft pulley to the engine front cover.

4. Hold the crankshaft pulley using the SST.
5. Tighten the crankshaft pulley lock bolt in the order shown with the following two steps using the SST (49 D032 316).

Tightening torque
1. 96-104 N-m (9.8-10.6 kgf-m, 70.9-76.7 ft-lbf)
2. 87°-93°

6. Remove the bolt (M6 X 1.0) installed to the crankshaft pulley.
7. Remove the SST from the camshaft.

8. Remove the SST installed in the cylinder block lower blind plug hole.
9. Rotate the crankshaft clockwise two turns and inspect the valve timing.
- If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

10. Install the cylinder block lower blind plug.

Tightening torque
18-22 N-m (1.9-2.2 kgf-m, 13.3-16.2 ft-lbf)

Cylinder Head Cover Installation Note

Caution
- Install the cylinder head cover within 10 min of applying the silicone sealant.

1. Apply silicone sealant to the mating faces as shown in the figure.

Thickness
4.0-7.0 mm (0.16-0.27 in)

2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order shown in the figure.

Tightening torque
8.0-9.5 N-m (81.6-96.8 kgf-cm, 71-84 in-lbf)