TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI]


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1.  Disconnect the negative battery cable.

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI].)

3.  Disconnect the wiring harness.

4.  Remove the high pressure fuel pump and high pressure fuel pump cover. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.0 DISI].)

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

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

7.  Disconnect the ventilation hose from the cylinder head cover.

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

9.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

10.  Set the front mudguard (RH) out of the way. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

11.  Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

12.  Loosen the water pump pulley bolts and remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI].)

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

14.  Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (ATX) (See DRIVE SHAFT REMOVAL/INSTALLATION.)

15.  Remove in the order indicated in the table.

16.  Install in the reverse order of removal.

17.  Start the engine. And inspect and adjust the following:

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

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1
Dipstick
2
Cylinder head cover
3
Crankshaft pulley lock bolt
4
Crankshaft pulley
5
Water pump pulley
6
Drive belt idler pulley
7
Drive belt idler pulley
8
No.3 engine mount
9
Front oil seal
10
Engine front cover
11
Chain tensioner
12
Tensioner arm
13
Chain guide
14
Timing chain
15
Oil pump chain tensioner
16
Oil pump driven sprocket
17
Oil pump chain
18
Crankshaft sprocket
19
Oil pump drive sprocket


Cylinder Head Cover Removal Note

1.  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.  Install the SST using the following procedures.

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Caution
•  Refer to the SST instruction manual for the basic handing procedure.
(1)  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber bolts.
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(2)  Install front foot No.2 to the left/right front shaft of the SST, then align the front shaft hole of the SST with the bolt 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.

2.  Support the engine using the SST.

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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.  Press the timing chain tensioner ratchet to the left using a thin flathead screwdriver (precision screwdriver) to unlock the plunger.

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2.  Slowly press the plunger back in the direction shown in the figure while pressing the ratchet.

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3.  Release the ratchet with the plunger still pressed down.

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4.  Press-in the plunger until the ratchet position is as indicated in the figure, and then insert the wire to lock the plunger.

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Oil Pump Driven Sprocket Removal 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 the oil pump driven sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.


Oil Pump Drive Sprocket Installation Note

1.  The oil pump drive sprocket has the assembly direction as shown in the figure.

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Oil Pump Driven Sprocket 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.  Install the oil pump driven sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Tightening torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}


Timing Chain Installation Note

1.  Install the SST to the camshaft as shown in the figure.

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2.  Install the timing chain.

3.  Remove the wire or paper clip from the chain tensioner piston and 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.
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Thickness
A: 2.2—3.2 mm {0.09—0.12 in}
B: 1.5—2.5 mm {0.060—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.  Tighten the engine front cover installation bolts in the order shown in the figure.

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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
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.

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—3
71—93 N·m {7.3—9.4 kgf·m, 53—68 ft·lbf}
4, 5
75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}


Crankshaft Pulley Lock Bolt Installation Note

1.  Install the SST to the camshaft as shown in the figure.

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2.  Verify that the No.1 cylinder is at TDC of the compression stroke. (The position counterweight contacts the 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
1st step: 96—104 N·m {9.8—10 kgf·m, 71—76 ft·lbf}
2nd step: 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 installed in 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 areas shown in the figure.

Caution
•  Install the cylinder head cover before the applied silicone sealant starts to harden.
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Thickness
5.0 mm {0.20 in}

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

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