TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7]

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Warning

• 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 injures 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 [MZI-3.7].)

• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.

Note

• The following procedure “TIMING CHAIN REMOVAL/INSTALLATION” is performed after the engine and transaxle component is removed from the vehicle. (See ENGINE REMOVAL/INSTALLATION [MZI-3.7].)

1. Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZI-3.7].)

2. Remove the engine and transaxle component. (See ENGINE REMOVAL/INSTALLATION [MZI-3.7].)

3. Secure the engine and transaxle component using a hoist and the SST.

Warning

• Protect and stabilize the lowered engine and transaxle component with crossties to prevent injury or damage due to roll over.

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4. Remove the dynamic chamber and throttle body as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZI-3.7].)

6. Remove the dipstick.

7. Remove the power steering oil pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7].)

8. Remove the power steering oil pump. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L.H.D.].)(See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [R.H.D.].)

9. Remove in the order indicated in the table.

10. Install in the reverse order of removal.

11. Start the engine and:

(1) Inspect the runout and contact on the pulley and belt.

(2) Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.

(3) Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZI-3.7].)

(4) Engine accessories operation.

12. Perform a road test.

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Crankshaft Pulley Lock Bolt Removal Note

1. Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZI-3.7].)

2. Set a flathead screwdriver to the drive plate in the position indicated in the figure to lock the crankshaft rotation.

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3. Remove the crankshaft pulley lock bolt and washer.

Crankshaft Pulley Removal Note

1. Remove the washer from the crankshaft pulley lock bolt, install a suitable spacer (thickness: approx. 14 mm {0.55 in}, diameter: approx. 30 mm {1.18 in}), (similar to front shock absorber lower nut) to the crankshaft pulley lock bolt, and install the crankshaft pulley lock bolt to the crankshaft.

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2. Remove the crankshaft pulley using the SST.

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3. Remove the crankshaft pulley lock bolt and spacer.

Front Oil Seal Removal Note

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

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Cylinder Head Cover Removal Note

1. Remove the cylinder head cover bolts in the order shown.

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Cylinder Head Cover Oil Seal Removal Note

Note

• Inspect the OCV attachment hole seals and spark plug tube attachment hole seals. Remove the any damaged seals.

• The OCV attachment hole seals removal is shown, the spark plug tube attachment hole seals removal procedure is the same.

1. Tap the OCV attachment hole seals and spark plug tube attachment hole seals using the SSTs and hammer.

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Engine Front Cover and No.3 Engine Mount Bracket Removal Note

1. Loosen the engine front cover and No.3 engine mount bracket installation bolts in the order shown in the figure.

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2. Install 4 of the engine front cover bolts (finger tightened) into the 4 threaded holes in the engine front cover.

(1) Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.

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(2) Remove the engine front cover.

OCV Component Removal Note

1. Loosen the OCV component installation bolts in the order shown in the figure.

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Timing Chain Component Removal Note

Caution

• Do not rotate the crankshaft counterclockwise. The timing chains may bind, causing engine damage.

1. Turn the crankshaft clockwise so that the crankshaft keyway is in the 11 o’clock position. (This will position the No.1 cylinder at TDC.)

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Note

• Verify that there are timing marks in four locations on the timing chain. If any timing marks are missing, mark the timing chain.

• When marking the variable valve timing actuator (RH) side timing chain, change the mark color.

• When the timing chain is replaced with a new one, mark the new timing chain at the same positions as the removed timing chain.

2. Mark the timing chain at the position of each timing sprocket timing mark.

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3. Remove the timing chain in the following order.

(1) Chain tensioner

(2) Timing chain

(3) Tensioner arm

(4) Chain guide

(5) Crankshaft sprocket

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Timing Chain Component Installation Note

1. Verify that the crankshaft keyway is at 11 o’clock position.

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Note

• Of the four marked locations on the timing chain, align the mark that has a different color to the variable valve timing actuator (RH) side timing mark.

2. If the timing marks on the timing chain are not evident, place timing marks on the timing chain using an indelible ink marker.

Note

• The marked external links are not included in the count.

• When marking the variable valve timing actuator (RH) side timing chain (No.2), change the mark color.

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The number of external links

No.1—2 : 48

No.2—3 : 40

No.3—1 : 35

3. Place alignment marks on the timing chain corresponding to each of the alignment marks on the timing sprocket.

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4. Using a thin screwdriver, hold the chain tensioner ratchet lock mechanism away from the ratchet stem.

5. Slowly compress the plunger.

6. Hold the plunger using a approx. 1.5 mm {0.059 in} wire.

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7. Install the timing chain in the following order.

(1) Crankshaft sprocket

(2) Chain guide

(3) Tensioner arm

(4) Timing chain

(5) Chain tensioner

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Tightening torque

8.5—11.5 N·m {87—117 kgf·cm, 76—101 in·lbf}

8. Remove the retaining wire.

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OCV Component Installation Note

1. Tighten the OCV component installation bolts in the order shown in the figure.

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Engine Front Cover and No.3 Engine Mount Bracket Installation Note

1. Apply the silicon sealant (Loctite 5900) to the engine front cover shown in the figure.

Caution

• Install the engine front cover, No.3 engine mount bracket and engine front cover installation bolts before the applied sealant starts to harden.

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Silicon sealant thickness

A: 2.5—3.5 mm {0.099—0.137 in}

B: 5.0—6.0 mm {0.197—0.236 in}

2. Install the engine front cover and No.3 engine mount bracket.

(1) Tighten the engine front cover and No.3 engine mount bracket installation bolts in 4 steps in the order shown in the figure.

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Tightening torque

Step	Installation position	Tightening torque
1	1—6	10 N·m {102 kgf·cm, 89 in·lbf}
2	7—9	15 N·m {1.5 kgf·m, 11 ft·lbf}
3	1—6	20—28 N·m {2.1—2.8 kgf·m, 15—20 ft·lbf}
4	7—9	70—80 N·m {7.2—8.1 kgf·m, 52—59 ft·lbf}

(2) Tighten the engine front cover installation bolts in the order in 2 steps in the order shown in the figure.

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Tightening torque

1. Tighten to 10 N·m {102 kgf·cm, 89 in·lbf}.

2. Tighten to 20—28 N·m {2.1—2.8 kgf·m, 15—20 ft·lbf}.

Cylinder Head Cover Oil Seal Installation Note

Note

• Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

1. Push the OCV attachment hole seals and spark plug tube attachment hole seals slightly in by hand.

2. Tap the OCV attachment hole seals and spark plug tube attachment hole seals using the SST and hammer.

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Cylinder Head Cover Installation Note

1. Apply silicone sealant (Loctite 5900) to the mating faces as shown.

Caution

• Install the cylinder head cover installation bolts and studs before the applied sealant starts to harden.

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

3. Tighten the bolts in the order as shown.

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Tightening torque

8.5—11.5 N·m {87—117 kgf·cm, 76—101 in·lbf}

Front Oil Seal Installation Note

Note

• Apply clean engine oil to the front oil seal bore in the engine front cover.

1. Push the front oil seal slightly in by hand.

2. Tap the front oil seal in evenly using the SST and a hammer.

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Substitution SST

• 49 G028 203

Outer diameter: 58—70 mm {2.29—2.75 in}

Inner diameter: 56—58 mm {2.21—2.28 in}

Tube with board thickness 2 mm {0.079 in} or more

Crankshaft Pulley Installation Note

Note

• Lubricate the contact surface (exterior area of inner diameter) of the front oil seal with clean engine oil.

1. Install the crankshaft pulley, washer, and SST to the crankshaft.

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2. Tighten the SST nut and install the crankshaft pulley.

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Crankshaft Pulley Lock Bolt Installation Note

1. Set a flathead screwdriver to the drive plate in the position indicated in the figure to lock the crankshaft rotation.

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2. Tighten the new crankshaft pulley lock bolt in four steps.

(1) Tighten to 140 N·m {14 kgf·m, 103 ft·lbf}.

(2) Loosen 360 ° (one full turn) in reverse order.

(3) Tighten to 47—53 N·m {4.8—5.4 kgf·m, 35—39 ft·lbf}.

(4) Tighten 85 °—95 °.

3. Install the starter. (See STARTER REMOVAL/INSTALLATION [MZI-3.7].)

1	Drive belt auto tensioner
2	Crankshaft pulley lock bolt (See Crankshaft Pulley Lock Bolt Removal Note.) (See Crankshaft Pulley Lock Bolt Installation Note.)
3	Crankshaft pulley (See Crankshaft Pulley Removal Note.) (See Crankshaft Pulley Installation Note.)
4	Front oil seal (See Front Oil Seal Removal Note.) (See Front Oil Seal Installation Note.)
5	Cylinder head cover (LH) (See Cylinder Head Cover Removal Note.) (See Cylinder Head Cover Installation Note.)
6	Cylinder head cover (RH) (See Cylinder Head Cover Removal Note.) (See Cylinder Head Cover Installation Note.)
7	Cylinder head cover oil seal (LH) (See Cylinder Head Cover Oil Seal Removal Note.) (See Cylinder Head Cover Oil Seal Installation Note.)
8	Cylinder head cover oil seal (RH) (See Cylinder Head Cover Oil Seal Removal Note.) (See Cylinder Head Cover Oil Seal Installation Note.)
9	No.3 engine mount bracket (See Engine Front Cover and No.3 Engine Mount Bracket Removal Note.) (See Engine Front Cover and No.3 Engine Mount Bracket Installation Note.) (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [MZI-3.7].)
10	Engine front cover (See Engine Front Cover and No.3 Engine Mount Bracket Removal Note.) (See Engine Front Cover and No.3 Engine Mount Bracket Installation Note.)
11	OCV component (LH) (See OCV Component Removal Note.) (See OCV Component Installation Note.)
12	OCV component (RH) (See OCV Component Removal Note.) (See OCV Component Installation Note.)
13	Chain tensioner
14	Timing chain component (See Timing Chain Component Removal Note.) (See Timing Chain Component Installation Note.)