TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6]

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Warning
•  Do not remove the jack from the engine with the bolt of engine mount No. 3 removed because the engine may fall off and cause a serious accident.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

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

4.  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.)

5.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.5, MZR 1.6].)

6.  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 1.5, MZR 1.6].)
With set bolt
1.  Set the air cleaner cover out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)
2.  Remove the fresh-air duct and the air cleaner case as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

7.  Remove the coolant reserve tank with the hoses still connected. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

8.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

9.  Set the wiring harness out of the way.

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

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11.  Set the cooler pipe and the cooler hose out of the way. (With A/C) (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

12.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

13.  Disconnect the crankshaft position (CKP) sensor connector.

14.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

15.  Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

16.  Disconnect the ground cable from the No.3 engine mount.

Tightening torque
35—50 N·m {3.6—5.0 kgf·m, 26—36 ft·lbf}

17.  Remove in the order indicated in the table.

18.  Install in the reverse order of removal.

19.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.5, MZR 1.6].)

20.  Start the engine, and inspect the following and adjust them if necessary.

(1)  Leakage of engine oil and engine coolant.
(2)  Pulley and belt for runout and contact
(3)  Ignition timing and idle speed. Verify the amount of CO and HC. (See ENGINE TUNE-UP [MZR 1.5, MZR 1.6].)

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1
Cylinder head cover
(See Cylinder Head Cover Installation Note.)
2
Crankshaft pulley lock bolt
(See Crankshaft Pulley Lock Bolt Removal Note.)
(See Crankshaft Pulley Lock Bolt Installation Note.)
3
Crankshaft pulley
4
Drive belt auto tensioner
5
Idler
6
Dipstick pipe
7
No.3 engine mount
(See No.3 Engine Mount Removal Note.)
(See No.3 Engine Mount Installation Note.)
8
OCV
9
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [MZR 1.5, MZR 1.6].)
10
Engine front cover
(See Engine Front Cover Installation Note.)
11
Chain tensioner
(See Chain Tensioner Removal Note.)
12
Chain tensioner arm
13
Chain guide
14
Timing chain
(See Timing Chain Removal Note.)
(See Timing Chain Installation Note.)
15
Crankshaft sprocket
16
Key


Crankshaft Pulley Lock Bolt Removal Note

Caution
•  To prevent damaging the crankshaft pulley, protect the crankshaft pulley with a clean rag so that the SST and the crankshaft pulley do not come into contact each other.

1.  Fix the crankshaft pulley using the SSTs, and remove the crankshaft pulley lock bolt.

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No.3 Engine Mount Removal Note

1.  Support the engine using the either of the following procedures.

Caution
•  When supporting the housing, verify that any switches and wiring harnesses are not caught.
•  Support the clutch housing (MTX) or the converter housing (ATX, CVT) using a jack with a wood slab of appropriate size inserted to secure the housing.
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•  Support the engine using an engine jack.
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Chain Tensioner Removal Note

1.  Push down the link plate of the timing chain tensioner using a thin flathead screwdriver (precision screwdriver), and release the plunger lock.

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2.  Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.

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3.  Free the link plate with the plunger still pressed down.

4.  Release the pressure slightly from the plunger, and move the plunger back and forth 2—3 mm{0.08—0.11 in}.

5.  Insert an approx. 1.5 mm {0.06 in} wire or the paper clip where the link plate hole and the tensioner body hole overlap to fix the link plate and lock the plunger.

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Timing Chain Removal Note

1.  Rotate the crankshaft clockwise and align the key groove of the crankshaft sprocket to the timing mark, and then position the No.1 cylinder to TDC.

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2.  Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

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3.  Remove the timing chain.


Timing Chain Installation Note

1.  Align the key groove of the crankshaft sprocket to the timing mark, and then position the No.1 cylinder to TDC.

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2.  Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

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3.  Install the timing chain.

4.  After installing the chain adjuster, remove the wire or the paper clip installed to the chain tensioner, and apply tension to the timing chain. (Remove the installed stopper when installing the new chain tensioner.)

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5.  Verify that there is no slack on the timing chain, and then verify that each sprocket is positioned in the proper place again.

6.  Rotate the crankshaft clockwise twice, and then inspect the valve timing.


Engine Front Cover Installation Note

Caution
•  Install the engine front cover before the applied silicone sealant starts to harden.

1.  Apply the silicon sealant to the engine front cover as shown in the figure.

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Thickness
2—4 mm {0.08—0.15 in}

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

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Bolt number

Tightening torque
1—6, 8, 10,
12—15, 17, 18
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
7, 11, 16
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}
9
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


No.3 Engine Mount Installation Note

1.  Tighten the No.3 engine mount installation stud bolts.

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2.  Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts.

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

3.  Tighten the installation bolts and nuts in the order shown in the figure.

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Tightening torque
1 (nuts): 44—61 N·m {4.5—6.2 kgf·m, 33—44 ft·lbf}
2 (bolts): 71—93 N·m {7.3—9.4 kgf·m, 53—68 ft·lbf}


Crankshaft Pulley Lock Bolt Installation Note

Caution
•  To prevent damaging the crankshaft pulley, protect the crankshaft pulley with a clean rag so that the SST and the crankshaft pulley do not come into contact each other.

1.  Fix the crankshaft pulley using the SSTs.

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2.  Tighten the crankshaft pulley lock bolt.

Tightening torque
157—167 N·m {16.1—17 kgf·m, 116—123 ft·lbf}


Cylinder Head Cover Installation Note

1.  Apply silicon sealant as shown in the figure.

Caution
•  Install the cylinder head cover before the applied silicone sealant starts to harden.
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Thickness
2—6 mm {0.08—0.23 in}
Length
6—26 mm {0.24—1.02 in}

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

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Tightening torque
7—10 N·m {72—101 kgf·cm, 62—88 in·lbf}