TIMING CHAIN REMOVAL/INSTALLATION [MZR-CD 2.2]

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Note
•  If the timing chain is replaced, always perform each adjustment procedure using the following steps.

STEP

ACTION

PAGE/CONDITION
1
Replace the timing chain.
—
2
Start the engine.
—
3
Perform the injection amount correction procedure.
Engine coolant temperature: 65—95 °C {149—203 °F}
Intake air temperature: 15—65 °C {59—149 °F}
Fuel temperature: 30—60 °C {86—140 °F}
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [MZR-CD 2.2].)
4
Perform the timing chain correction procedure.
Engine coolant temperature: 65—95 °C {149—203 °F}
Intake air temperature: 15—65 °C {59—149 °F}
Fuel temperature: 30—60 °C {86—140 °F}
(See TIMING CHAIN CORRECTION [MZR-CD 2.2].)
5
Perform after repair procedure.
(See AFTER REPAIR PROCEDURE [MZR-CD 2.2].)
6
Switch the ignition to off.
—

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

2.  Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZR-CD 2.2].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.  Disconnect the ventilation hose.

6.  Disconnect the following parts and set the fuel injector wiring harness out of the way.

•  Fuel injector connector
•  Boost sensor connector
•  Fuel pressure sensor connector
•  EGR cooler bypass valve control solenoid valve connector
•  Front harness-short cord connector
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7.  Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.  Remove the camshaft position sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

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.

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12.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR-CD 2.2].)

13.  Remove the crankshaft position sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

14.  Remove the fuel filter component with the hose still connected and set it out of the way. (L.H.D.) (See FUEL FILTER REMOVAL/INSTALLATION [MZR-CD 2.2].)

15.  Remove the coolant reserve tank with the hose still connected and set it out of the way. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

16.  Remove in the order shown in the table.

17.  Install in the reverse order of removal.

18.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

19.  Refill the engine oil. (See ENGINE OIL REPLACEMENT [MZR-CD 2.2].)

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

•  Leakage of engine oil and fuel.
•  Runout and contact of pulley and belt.
•  Idle speed. (See ENGINE TUNE-UP [MZR-CD 2.2].)

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1
Insulator
2
Cylinder head cover
(See Cylinder Head Cover Removal Note.)
(See Cylinder Head Cover Installation Note.)
3
Idler
4
Crankshaft pulley cover
5
Crankshaft pulley
6
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [MZR-CD 2.2].)
7
No.3 engine mount
(See No.3 Engine Mount Removal Note.)
(See No.3 Engine Mount Installation Note.)
8
Drive belt auto tensioner
(See Drive Belt Auto Tensioner Removal Note.)
(See Drive Belt Auto Tensioner Installation Note.)
9
Engine front cover
(See Engine Front Cover Installation Note.)
10
Timing chain tensioner
(See Timing Chain Tensioner Removal Note.)
11
Timing chain tensioner arm
12
Timing chain guide No.1
13
Timing chain guide No.2
14
Timing chain
(See Timing Chain Installation Note.)


Cylinder Head Cover Removal Note

1.  Remove the bolts in the order shown in the figure.

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No.3 Engine Mount Removal Note

1.  Detach the hose clip shown in the figure.

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2.  Remove the bracket bolt shown in the figure and set the bracket aside to prevent interference with the SST.

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3.  Install the SST using the following procedure.

Note
•  Refer to the SST instruction manual for the basic handing procedure.
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(1)  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber installation nut.
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(2)  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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(3)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.
(4)  Make sure each joint is securely tightened.

4.  Support the engine using the SST.

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5.  Remove the No.3 engine mount.


Drive Belt Auto Tensioner Removal Note

1.  Remove the drive belt auto tensioner installation bolt and nuts.

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2.  Remove the drive belt auto tensioner stud bolts.

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3.  Remove the drive belt auto tensioner.


Timing Chain Tensioner Removal Note

1.  Rotate the crankshaft clockwise and align the knock pin to the position shown in the figure. In this position, the No.1 cylinder is at the TDC of the compression stroke.

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2.  Push up the ratchet using a screwdriver and slowly compress the piston.

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3.  Hold the piston using a wire or paper clip.

4.  Remove the timing chain tensioner.


Timing Chain Installation Note

Caution
•  If the engagement of the internal and external links for the timing chain is reversed, new contact marks will be produced on the vacuum pump sprocket, damaging the sprocket and decreasing the NVH performance. Therefore, when installing the timing chain to the vacuum pump sprocket, position it to the original contact marks on the timing chain.
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Note
•  The reference and the 25th external link are the timing chain alignment marks.
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1.  Set the timing chain with the timing chain alignment mark aligned with the exhaust camshaft sprocket alignment mark as well as the crankshaft sprocket alignment mark.

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Engine Front Cover Installation Note

1.  Apply sealant as shown in the figure.

Caution
•  Temporarily tighten the engine front cover before the applied sealant starts to harden.
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Thickness
A: 2—4 mm {0.08—0.15 in}
B: 4—6 mm {0.16—0.23 in}

2.  Tighten the bolts in the order shown in the figure.

Caution
•  Remove the sealant from bolt threads before reusing any bolts.
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Tightening torque
1.  38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
2.  19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
3.  19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}


Drive Belt Auto Tensioner Installation Note

1.  Align the drive belt auto tensioner with the installation position and install the stud bolts.

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Tightening torque
3.4—4.9 N·m {35—49 kgf·cm, 31—43 in·lbf}

2.  Temporarily tighten the drive belt auto tensioner installation bolt and nuts.

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3.  Tighten the drive belt auto tensioner installation bolt and nuts.

Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Note
•  Verify that the stud bolt shown in the figure do not interfere with the drive belt auto tensioner.
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No.3 Engine Mount Installation Note

Note
•  When loosening the No.3 engine mount nuts, always tighten the No.3 engine mount bracket stud bolts. When the No.3 engine mount nuts are loosened, the No.3 engine mount bracket stud bolts could become loose.

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
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}


Cylinder Head Cover Installation Note

1.  Apply sealant as shown in the figure.

Caution
•  Install the cylinder head cover before the applied sealant starts to harden.
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Thickness
2—6 mm {0.1—0.2 in}

2.  After temporarily tightening bolt A, tighten it in the order shown in the figure.

Caution
•  If the oil seal is damaged, replace the oil seal.
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Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

3.  Tighten the bolts in the order shown in the figure.

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Tightening torque
7.0—9.5 N·m {72—96 kgf·cm, 62—84 in·lbf}