TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop]

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1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2.  Disconnect the negative battery cable.

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

4.  Disconnect the wiring harness.

5.  Remove the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

6.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

7.  Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

8.  Remove the ventilation hose.

9.  Remove the coolant reserve tank with the hose still connected and set it out of the way. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

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

11.  Remove the aerodynamic under cover No.2 and splash shield as a single unit. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

12.  Remove the nut shown in the figure and set the power steering pipe component out of the way.

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13.  Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

14.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

15.  Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (MTX) (See DRIVE SHAFT REMOVAL/INSTALLATION.)

16.  Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)

17.  Remove in the order indicated in the table.

18.  Install in the reverse order of removal.

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

•  Leakage of engine oil. (See ENGINE OIL LEVEL INSPECTION [MZR 2.0 DISI i-stop].)
•  Runout and contact of pulley and belt.
•  Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZR 2.0 DISI i-stop].)

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1
Dipstick
2
Cylinder head cover
(See Cylinder Head Cover Removal Note.)
(See Cylinder Head Cover Installation Note.)
3
Crankshaft pulley lock bolt
(See Crankshaft Pulley Lock Bolt Removal Note.)
(See Crankshaft Pulley Lock Bolt Installation Note.)
4
Crankshaft pulley
5
Water pump pulley
6
Drive belt auto tensioner
7
No.3 engine mount
(See No.3 Engine Mount Removal Note.)
(See No.3 Engine Mount Installation Note.)
8
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [MZR 2.0 DISI i-stop].)
9
Engine front cover
(See Engine Front Cover Installation Note.)
10
Chain tensioner
(See Chain Tensioner Removal Note.)
11
Tensioner arm
12
Chain guide
13
Timing chain
(See Timing Chain Installation Note.)
14
Oil pump chain tensioner
15
Oil pump driven sprocket
(SeeOil Pump Driven Sprocket Removal Note.)
(SeeOil Pump Driven Sprocket Installation Note.)
16
Oil pump chain
17
Crankshaft sprocket
18
Oil pump drive sprocket
(SeeOil Pump Drive Sprocket Installation Note.)


Cylinder Head Cover Removal Note

1.  Loosen the cylinder head cover bolts in the order shown in the figure.

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Crankshaft Pulley Lock Bolt Removal Note

1.  Rotate the crankshaft in the direction of the engine rotation and remove the cylinder block lower blind plug when the No. 1 cylinder is at the point prior to top dead center (TDC) of compression, then install the SST.

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2.  Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the compression stroke. (Until the counterweight contacts SST and stops.)

3.  Hold the crankshaft pulley by using the SSTs.

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No.3 Engine Mount Removal Note

Note
•  If the oil pan is removed, note that the method for securing the engine differs.

Oil pan is removed

1.  Install the SST using the following procedures.

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Caution
•  Refer to the SST instruction manual for the basic handing procedure.
(1)   Remove the installation bolt for the bracket securing the lower radiator hose.
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(2)   Set the bracket securing the lower radiator hose aside to prevent it from interfering with the front shaft of the SST (right side)
(3)  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber bolts.
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(4)  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.
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(5)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal. Make sure each joint is securely tightened.
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Oil pan is not removed

1.  Support the engine (oil pan) using a commercially available engine lifter.

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Chain Tensioner Removal Note

1.  Press the timing chain tensioner ratchet to the left using a thin flathead screwdriver (precision screwdriver) to unlock the plunger.

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2.  Slowly press the plunger back in the direction shown in the figure while pressing the ratchet.

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3.  Release the ratchet with the plunger still pressed down.

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4.  Press-in the plunger until the ratchet position is as indicated in the figure, and then insert the wire to lock the plunger.

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Oil Pump Driven Sprocket Removal 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.

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2.  Remove the oil pump driven sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.


Oil Pump Drive Sprocket Installation Note

1.  The oil pump drive sprocket has the assembly direction as shown in the figure.

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Oil Pump Driven Sprocket 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.

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2.  Install the oil pump driven sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Tightening torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}


Timing Chain Installation Note

1.  Install the SST to the camshaft as shown in the figure.

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2.  Install the timing chain.

3.  Remove the wire or paper clip from the chain tensioner piston and apply tension to the timing chain.


Engine Front Cover Installation Note

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

Caution
•  Install the engine front cover before the applied silicone sealant starts to harden.
•  Completely remove any oil, dirt, sealant, or other foreign matter adhering to the engine front cover and engine front cover installation surface. If any oil, dirt, sealant, or other foreign matter is not removed from the space between the engine front cover and engine front cover installation surface, it may cause a sealing malfunction.
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Thickness
A: 2.2—3.2 mm {0.09—0.12 in}
B: 1.5—2.5 mm {0.060—0.098 in}
C: 2.2—4.3 mm {0.09—0.16 in}
D: 3.3—4.3 mm {0.13—0.16 in}

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

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No.

Tightening torque
1―18
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
19―22
40—55 N·m {4.1—5.6 kgf·m, 30—40 ft·lbf}
23
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}


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.

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Tightening torque
7—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

2.  Temporarily tighten the No.3 engine mount installation bolts and nuts.

Note
•  Do not tighten the bolts and nuts during this step.

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

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Tightening torque
Nut: 75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}
Bolt: 71—93 N·m {7.3—9.4 kgf·m, 53—68 ft·lbf}


Crankshaft Pulley Lock Bolt Installation Note

1.  Install the SST to the camshaft as shown in the figure.

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2.  Verify that the No.1 cylinder is at TDC of the compression stroke. (The position counterweight contacts the SST.)

3.  To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0 length 25—35 mm {1.0—1.3 in}), fix the crankshaft pulley to the engine front cover.

Note
•  Do not tighten the bolt during this step.
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4.  Install the SSTs to the crankshaft pulley, lock the crankshaft against rotation, and tighten the crankshaft pulley lock bolt using the following two steps using the SST (49 D032 316).

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Tightening procedure
1st step: 96—104 N·m {9.8—10 kgf·m, 71—76 ft·lbf}
2nd step: 87—93°

5.  Remove the bolt (M6 X 1.0 length 25—35 mm {1.0—1.3 in}) installed to the crankshaft pulley.

6.  Remove the SST from the camshaft.

7.  Remove the SST installed in the cylinder block lower blind plug hole.

8.  Rotate the crankshaft clockwise two turns and inspect the valve timing.

•  If not aligned, repeat from Step 1.

9.  Install the cylinder block lower blind plug.

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Tightening torque
18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}


Cylinder Head Cover Installation Note

1.  Apply silicone sealant to the areas shown in the figure.

Caution
•  Install the cylinder head cover before the applied silicone sealant starts to harden.
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Thickness
5.0 mm {0.20 in}

2.  Tighten the cylinder head cover bolts in the order shown in the figure.

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Tightening torque
8.0—9.5 N·m {82—96 kgf·cm, 71—84 in·lbf}