TIMING CHAIN REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)]

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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 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 [MZ-CD 1.6 (Y6)].)

1.  Remove the following parts:

(1)  Timing belt (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)].)
(2)  Charge air cooler pipe and hose (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(3)  Air pipe (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(4)  EGR valve (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(5)  EGR pipe (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(6)  Upper cylinder head cover (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(7)  Fuel injectors (See FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(8)  Intake manifold (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(9)  CMP sensor
(10)  Fuel filter protector and fuel filter (See FUEL FILTER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(11)  Vacuum pump (See VACUUM PUMP REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 EMISSION LEVEL)].)

2.  Remove in the order indicated in the table.

3.  Install in the reverse order of removal.

4.  Start the engine.

5.  Inspect the pulley and belt for runout and contact and adjust them if necessary.

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1
Camshaft pulley
(See Camshaft Pulley Removal Note.)
(See Camshaft Pulley Installation Note.)
2
Camshaft seal plate
3
Camshaft oil seal
(See Camshaft Oil Seal Installation Note.)
4
Fuel filter bracket
5
Lower cylinder head cover and camshaft component
(See Lower Cylinder Head Cover And Camshaft Component Removal Note.)
(See Lower Cylinder head Cover And Camshaft Component Installation Note.)
6
Camshaft cap
(See Camshaft Cap Removal Note.)
7
Camshaft
(See Camshaft Installation Note.)
8
Timing chain tensioner
9
Timing chain
10
Lower cylinder head cover


Camshaft Pulley Removal Note

1.  Lock the camshaft using the SSTs.

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2.  Remove the camshaft pulley installation bolt.


Lower Cylinder Head Cover And Camshaft Component Removal Note

1.  Remove the lower cylinder head cover installation bolts and studs in the order shown in the figure.

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Camshaft Cap Removal Note

Caution
•  Keep the camshaft caps and camshafts in order for installation.

Camshaft Installation Note

Note
•  The links of the timing chain must align with the timing marks on the camshaft sprockets.

1.  Align the links of the timing chain with the timing marks on the camshaft sprockets.

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Lower Cylinder head Cover And Camshaft Component Installation Note

1.  Clean the mating surfaces of the cylinder head and lower cylinder head cover.

2.  Apply the sealant to the mating surface of the cylinder head.

Caution
•  Install the lower cylinder head cover before the applied silicone sealant starts to harden.
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Caution
•  Install the lower cylinder head cover before the applied silicone sealant starts to harden.
Diameter
2.5 mm {0.098 in}

3.  Align the lower cylinder head cover to the cylinder head using the SSTs.

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4.  Tighten the lower cylinder head cover installation bolts and studs in two steps in the order shown in the figure.

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Tightening torque
1.  5 N·m {51 kgf·cm, 44 in·lbf}
2.  10 N·m {102 kgf·cm, 89 in·lbf}


Camshaft Oil Seal Installation Note

Note
•  A new camshaft oil seal is supplied with an alignment and protection sleeve that must be removed during the following installation.

1.  Apply clean engine oil to a new camshaft oil seal.

2.  Install the camshaft oil seal using the SSTs.

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Camshaft Pulley Installation Note

1.  Lock the camshaft using the SSTs.

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2.  Install the camshaft pulley installation bolt