VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5]

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Caution

•  Remove the variable valve timing actuator as a single unit with the camshaft sprocket.

1.  Disconnect the negative battery cable.

2.  Perform the following procedure.

Without set bolt

1.  Remove the fresh-air duct and the air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

With set bolt

1.  Set the air cleaner cover out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

2.  Remove the fresh-air duct and the air cleaner case as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

3.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

4.  Disconnect the ventilation hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

5.  Set the vacuum hose out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

6.  Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

7.  Remove the splash shield (RH). (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

8.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

9.  Remove the engine front cover blind plug as shown in the figure.

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10.  Insert a M6 bolt (45 to 80 mm length bolt with threads to the end) into the service hole (right side) by hand as shown in the figure. Pull back the inserted bolt approx. 2 mm from where it contacts the tensioner arm, and set the bolt in a position slightly outward of the tensioner arm.

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11.  Release tension on the timing chain.

(1)  Press down the link plate of the chain tensioner from the service hole on the left side using a thin flathead screwdriver (precision screwdriver) as shown in the figure. Then rotate the crank pulley backwards (counterclockwise) with the plunger lock released.

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Note

•  When the crankshaft pulley is turned counterclockwise, the timing chain loosens because the tensioner arm is pressed by the timing chain and the plunger of the chain tensioner is pressed in.

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(2)  Insert the M6 bolt installed to the engine front cover to the position where it catches the inside of the rib on the tensioner arm.

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Note

•  When the timing chain loosens, the tensioner arm moves to the position shown in the figure and presses the M6 bolt to secure the tensioner arm.

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12.  Fix the camshaft using a wrench on the cast hexagon. Remove the camshaft sprocket installation bolt.

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13.  Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way.

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14.  Loosen the camshaft cap installation bolts in two or three steps in the order shown in the figure, and remove the camshaft caps.

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15.  Remove the intake camshaft and variable valve timing actuator as a single unit.

16.  Lock the camshaft against rotation by holding the camshaft with the vise and securing the cast hexagon with a wrench.

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17.  Loosen the variable valve timing actuator installation bolt, and then remove the variable valve timing actuator.

18.  Install the variable valve timing actuator.

19.  Tighten the variable valve timing actuator installation bolt.

20.  Align the timing marks on the crank pulley and the front cover, and then align the No.1 cylinder to the TDC.

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21.  Install the intake camshaft and variable valve timing actuator with the No.1 cylinder so that it is near TDC of the compression stroke.

22.  Install the camshaft caps to the position of a carved seal number to shown in the figure, and tighten the camshaft installation bolts in two or three steps uniformly in the order shown in the figure.

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23.  Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

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24.  Fix the camshaft using a wrench on the cast hexagon. Install the camshaft sprocket installation bolt.

25.  Remove the M6 bolt holding the tensioner arm.

26.  Verify that there is no slack in the timing chain, and then verify that the marks on the camshaft sprocket and the crank pulley are aligned.

27.  Inspect the valve timing by rotating the crankshaft clockwise twice.

28.  Install the new engine front cover blind plug.

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29.  Install the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

30.  Install the splash shield (RH). (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

31.  Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

32.  Connect the ventilation hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

33.  Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

34.  Install the fresh-air duct and the air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)