TIMING CHAIN REMOVAL/INSTALLATION [MZR-CD 2.2]

TIMING CHAIN REMOVAL/INSTALLATION [MZR-CD 2.2]SM2444613

id0110f2801000

Note

• If the timing chain is replaced, always perform each adjustment procedure using the following steps.

STEP	ACTION	PAGE/CONDITION
1	Replace the timing chain.	—
2	Start the engine.	—
3	Perform the injection amount correction procedure.	Engine coolant temperature: 65—95 °C {149—203 °F} Intake air temperature: 15—65 °C {59—149 °F} Fuel temperature: 30—60 °C {86—140 °F} (See FUEL INJECTOR INJECTION AMOUNT CORRECTION [MZR-CD 2.2].)
4	Perform the timing chain correction procedure.	Engine coolant temperature: 65—95 °C {149—203 °F} Intake air temperature: 15—65 °C {59—149 °F} Fuel temperature: 30—60 °C {86—140 °F} (See TIMING CHAIN CORRECTION [MZR-CD 2.2].)
5	Perform after repair procedure.	(See AFTER REPAIR PROCEDURE [MZR-CD 2.2].)
6	Switch the ignition to off.	—

1.Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

2.Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZR-CD 2.2].)

3.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.Disconnect the ventilation hose from the cylinder head cover.

6.Disconnect the following parts and set the fuel injector wiring harness out of the way.

• Fuel injector connector

• Boost sensor connector

• Fuel pressure sensor connector

• EGR cooler bypass valve control solenoid valve connector

• Front harness-short cord connector

acxwzw00001949

7.Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.Remove the camshaft position sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.Remove the front wheel and tire. (RH) (See GENERAL PROCEDURES (SUSPENSION).)

10.Remove the under cover.

11.Set the front mudguard (RH) out of the way.

12.Remove the front splash shield (RH).

13.Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR-CD 2.2].)

14.Remove the crankshaft position sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

15.Remove in the order shown in the table.

16.Install in the reverse order of removal.

17.Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

18.Refill the engine oil. (See ENGINE OIL REPLACEMENT [MZR-CD 2.2].)

19.Start the engine. And inspect and adjust the following:

• Leakage of engine oil and fuel.

• Runout and contact of pulley and belt.

• Verify the idle speed. (See ENGINE TUNE-UP [MZR-CD 2.2].)

acxwzw00000395

1	Insulator
2	Cylinder head cover (See Cylinder Head Cover Removal Note.) (See Cylinder Head Cover Installation Note.)
3	Idler
4	Crankshaft pulley cover
5	Crankshaft pulley
6	Front oil seal (See FRONT OIL SEAL REPLACEMENT [MZR-CD 2.2].)
7	No.3 engine mount (See No.3 Engine Mount Removal Note.) (See No.3 Engine Mount Installation Note.) (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [MZR-CD 2.2].)
8	Drive belt auto tensioner (See Drive Belt Auto Tensioner Removal Note.) (See Drive Belt Auto Tensioner Installation Note.)
9	Engine front cover (See Engine Front Cover Installation Note.)
10	Timing chain tensioner (See Timing Chain Tensioner Removal Note.)
11	Timing chain tensioner arm
12	Timing chain guide No.1
13	Timing chain guide No.2
14	Timing chain (See Timing Chain Installation Note.)

Cylinder Head Cover Removal Note

1.Remove the bolts in the order shown in the figure.

acxwzw00001950

No.3 Engine Mount Removal Note

1.Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

3.Remove the air cleaner and air cleaner bracket. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.To install the front shaft (RH) of the SST, remove the clip shown the figure.

acxwzw00001951

5.Remove the nut and set the cooler hose (LO) out of the way in the direction shown in the figure.

acxwzw00001952

6.Install the SST using the following procedure.

Caution

• Refer to the SST instruction manual for the basic handing procedure.

acxwzw00001953

(1)As shown in the figure, set the rear shafts of the SST to the left and right shock absorber bolts.

acxwzw00001954

(2)Temporarily tighten the bolt (M6 x 1.0) to the air cleaner bracket installation position and install front foot No. 2 to the left/right front shaft of the SST, and align the front shaft hole of the SST with the bolt as shown in the figure.

acxwzw00001955

(3)Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.

(4)Make sure each joint is securely tightened.

7.Support the engine using the SSTs.

acxwzw00001956

8.Remove the No.3 engine mount.

Drive Belt Auto Tensioner Removal Note

1.Remove the drive belt auto tensioner installation bolt and nuts.

acxwzw00001957

2.Remove the drive belt auto tensioner stud bolts.

acxwzw00001958

3.Remove the drive belt auto tensioner.

Timing Chain Tensioner Removal Note

1.Rotate the crankshaft clockwise and align the knock pin to the position shown in the figure. In this position, the No.1 cylinder is at the TDC of the compression stroke.

acxwzw00001959

2.Push up the ratchet using a screwdriver and slowly compress the piston.

acxwzw00001960

3.Hold the piston using a wire or paper clip.

4.Remove the timing chain tensioner.

Timing Chain Installation Note

Caution

• If the engagement of the internal and external links for the timing chain is reversed, new contact marks will be produced on the vacuum pump sprocket, damaging the sprocket and decreasing the NVH performance. Therefore, when installing the timing chain to the vacuum pump sprocket, position it to the original contact marks on the timing chain.

acxwzw00001820

Note

• The reference and the 25th external link are the timing chain alignment marks.

acxwzw00001961

1.Set the timing chain with the timing chain alignment mark aligned with the exhaust camshaft sprocket alignment mark as well as the crankshaft sprocket alignment mark.

acxwzw00001962

Engine Front Cover Installation Note

1.Apply sealant as shown in the figure.

Caution

• Temporarily tighten the engine front cover before the applied sealant starts to harden.

acxwzw00001963

Thickness

A: 2—4 mm {0.08—0.15 in}

B: 4—6 mm {0.16—0.23 in}

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

Caution

• Remove the sealant from bolt threads before reusing any bolts.

acxwzw00001964

Tightening torque

1. 38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}

2. 19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

3. 19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

Drive Belt Auto Tensioner Installation Note

1.Align the drive belt auto tensioner with the installation position and install the stud bolts.

acxwzw00001958

Tightening torque

3.4—4.9 N·m {35—49 kgf·cm, 31—43 in·lbf}

2.Temporarily tighten the drive belt auto tensioner installation bolt and nuts.

3.Tighten the drive belt auto tensioner installation bolt and nuts.

acxwzw00001957

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Note

• Verify that the stud bolt shown in the figure do not interfere with the drive belt auto tensioner arm.

acxwzw00001965

No.3 Engine Mount Installation Note

Note

• When loosening the No.3 engine mount nuts, always tighten the No.3 engine mount stud bolts. When the No.3 engine mount nuts are loosened, the No.3 engine mount stud bolts could become loose.

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