TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]

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1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

4.  Disconnect the wiring harness.

5.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

6.  Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

7.  Remove the ventilation hose.

8.  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, MZR 2.5].)

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

10.  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.)

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

MZR 2.0

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MZR 2.5

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12.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

13.  Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

14.  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. (MZR 2.0) (See A/C COMPRESSOR REMOVAL/INSTALLATION.)

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 in the order indicated in the table.

17.  Install in the reverse order of removal.

18.  Start the engine, and inspect and adjust the following:

•  Leakage of engine oil. (See ENGINE OIL LEVEL INSPECTION [MZR 2.0, MZR 2.5].)
•  Runout and contact of pulley and belt.
•  Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZR 2.0, MZR 2.5].)

MZR 2.0

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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, MZR 2.5].)
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 sprocket
(See Oil Pump Sprocket Removal/Installation Note.)
16
Oil pump chain
17
Crankshaft sprocket

MZR 2.5

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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
Idler pulley
7
Idler pulley
8
No.3 engine mount
(See No.3 Engine Mount Removal Note.)
(See No.3 Engine Mount Installation Note.)
9
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [MZR 2.0, MZR 2.5].)
10
Engine front cover
(See Engine Front Cover Installation Note.)
11
Chain tensioner
(See Chain Tensioner Removal Note.)
12
Tensioner arm
13
Chain guide
14
Timing chain
(See Timing Chain Installation Note.)
15
Oil pump chain tensioner
16
Oil pump sprocket
(See Oil Pump Sprocket Removal/Installation Note.)
17
Oil pump chain
18
Crankshaft sprocket


Cylinder Head Cover Removal Note

1.  Remove the purge solenoid valve installation bracket with the evaporative hose still connected and set it out of the way.

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2.  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.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

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

2.  Slowly compress the tensioner piston.

3.  Hold the tensioner piston using a 1.5 mm {0.059 in} wire or paper clip.

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Oil Pump Sprocket Removal/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.  Remove/install the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Tightening torque
Silver bolt: 20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}
Black bolt: 26—36 N·m {2.7—3.6 kgf·m, 20—26 ft·lbf}


Timing Chain Installation Note

1.  Install the SST to the camshaft as shown.

Europe

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Except Europe

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2.  Install the timing chain.

3.  Remove the retaining wire or paper clip from the auto tensioner to 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.

MZR 2.0

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Thickness
A: 2.2—3.2 mm {0.087—0.125 in}
B: 1.5—2.5 mm {0.059—0.098 in}

MZR 2.5

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Thickness
A: 2.2—3.2 mm {0.09—0.12 in}
B: 1.5—2.5 mm {0.06—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.  Install the engine front cover bolts in the order as shown.

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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 (MZR 2.0)
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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No.

Tightening torque
1
75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}
2
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.

Europe

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Except Europe

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

3.  To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0), fix the crankshaft pulley to the engine front cover.

Note
•  Do not tighten the bolt during this step.
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4.  Hold the crankshaft pulley using the SSTs.

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5.  Tighten the crankshaft pulley lock bolt in the order shown in the following two steps using the SST (49 D032 316).

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

6.  Remove the bolt (M6 X 1.0) installed to the crankshaft pulley.

7.  Remove the SST from the camshaft.

8.  Remove the SST from the cylinder block lower blind plug hole.

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

•  If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

10.  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 mating faces as shown.

Caution
•  Install the cylinder head cover before the applied silicone sealant starts to harden.
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Thickness
4.0—7.0 mm {0.16—0.27 in}

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

3.  Tighten the bolts in the order shown.

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

4.  Install the purge solenoid valve installation bracket.

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