VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6]

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Caution
•  Remove the variable valve timing actuator as a single unit with the camshaft sprocket.

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

2.  Disconnect the negative battery cable.

3.  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].)

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

5.  Set the wiring harness out of the way.

6.  Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

7.  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.)

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

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

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10.  Remove the engine front cover blind plug as shown in the figure.

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11.  Insert a M6 bolt (45 to 80 mm length bolt with threads to the end) into the right-side service hole shown in the figure, and set the bolt at a slightly outward position by loosening it approx. 2 mm from where it contacts the tensioner arm.

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12.  Release tension on the timing chain.

Note
•  When the crankshaft pulley is turned counterclockwise, the timing chain loosens because the tensioner arm is pressed by the timing chain and the plunger of the chain tensioner is pressed in.
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•  When the timing chain loosens, the tensioner arm moves to the position shown in the figure and presses the M6 bolt in, which secures the tensioner arm.
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(1)  Press down the link plate of the chain tensioner from the service hole on the left side using a thin flathead screwdriver (precision screwdriver) as shown in the figure. Then rotate the crank pulley backwards (counterclockwise) with the plunger lock released.
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(2)  Rotate the M6 bolt installed to the front cover by hand and insert it to the position where it catches the inside of the rib on the tensioner arm.
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13.  Fix the camshaft using a wrench on the cast hexagon. Remove the camshaft sprocket installation bolt.

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14.  Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way.

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15.  Loosen the camshaft cap installation bolts in two or three steps in the order shown in the figure, and remove the camshaft caps.

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16.  Remove the intake camshaft and variable valve timing actuator as a single unit.

17.  Lock the camshaft against rotation by holding the camshaft with the vise and securing the cast hexagon with a wrench.

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18.  Loosen the variable valve timing actuator installation bolt, and then remove the variable valve timing actuator.

19.  Install the variable valve timing actuator.

20.  Tighten the variable valve timing actuator installation bolt.

Tightening torque
50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}

21.  Align the timing marks on the crank pulley and the front cover, and then align the No.1 cylinder to the TDC.

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22.  With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timing actuator and the camshaft on the intake air side as a single unit.

23.  Install the camshaft caps to the position of a carved seal number to shown in the figure, and tighten the camshaft installation bolts in two or three steps uniformly in the order shown in the figure.

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Tightening torque
12—14 N·m {123—142 kgf·cm, 107—123 in·lbf}

24.  Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

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25.  Fix the camshaft using a wrench on the cast hexagon. Install the camshaft sprocket installation bolt.

Tightening torque
50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}

26.  Remove the M6 bolt holding the tensioner arm.

27.  Verify that there is no slack in the timing chain, and then verify that the marks on the camshaft sprocket and the crank pulley are aligned.

28.  Inspect the valve timing by rotating the crankshaft clockwise twice.

29.  Install the new engine front cover blind plug.

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Tightening torque
3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}

30.  Install the nut shown in the figure.

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

32.  Install 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.)

33.  Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

34.  Install the wiring harness.

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

36.  Install the fresh-air duct and the air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

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

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