TIMING CHAIN REMOVAL/INSTALLATION [L3 Turbo]

id0110b3801000

1. Disconnect the negative battery cable.

2. Remove the under cover.

3. Remove the front tire (RH).

4. Remove the splash shield (RH).

5. Remove the charge air cooler. (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

6. Remove the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [L3 Turbo].)

7. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

8. Disconnect the OCV connector.

9. Disconnect the CMP sensor connector.

10. Disconnect the P/S oil pump connector.

11. Remove the ventilation hose.

12. Remove the cylinder head cover. (See Cylinder Head Cover Removal Note.)

13. Loosen the water pump pulley installation bolt and remove the drive belt. (See DRIVE BELT REPLACEMENT [L3 Turbo].)

14. Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [L3 Turbo].)

15. Remove the P/S oil pump with the hoses and pipes still connected. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

  Note
  • Position and secure the P/S oil pump out of the way with a rope or wire.

16. Remove in the order indicated in the figure.

17. Install in the reverse order of removal.

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

  (1) Bleed the air from the cooling system. (See ENGINE COOLANT REPLACEMENT [L8, LF, L3, L3 Turbo].)

  (2) Engine oil amount (See ENGINE OIL LEVEL INSPECTION [L3 Turbo].)

  (3) Runout and contact of pulley and belt.

  (4) Ignition timing, idle speed, and idle mixture (CO and HC) verification (See ENGINE TUNE-UP [L3 Turbo].)

19. Perform a road test and verify that there is no abnormal vibration or noise.

am6zzw00007183

1 | Cylinder head cover (See Cylinder Head Cover Removal Note.) (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 | Water pump pulley
5 | Front drive belt idler pulley
6 | Engine ground
7 | No. 3 engine mount rubber, No. 3 Engine joint bracket (See No.3 Engine Mount Rubber, No.3 Engine Joint Bracket Removal Note.) (See No.3 Engine Mount Rubber, No.3 Engine Joint Bracket Installation Note.)
8 | Engine front cover (See Engine Front Cover Installation Note.)
9 | Front oil seal (See Engine Front Cover Removal Note.) (See Front Oil Seal 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 jet
15 | Oil pump chain tensioner
16 | Oil pump chain guide
17 | Oil pump driven sprocket (See Oil Pump Driven Sprocket Removal Note.) (See Oil Pump Driven Sprocket Installation Note.)
18 | Oil pump chain
19 | Crankshaft sprocket
20 | Oil pump drive sprocket (See Oil Pump Drive Sprocket Installation Note.)

Cylinder Head Cover Removal Note

1. Loosen the cylinder head cover bolts in the order shown in the figure.

am6zzw00007184

Crankshaft Pulley Lock Bolt Removal Note

1. Remove the cylinder block lower blind plug and install the SST.

am6zzw00007185

2. Rotate the crankshaft clockwise so that the No.1 cylinder is at TDC of the compression stroke. (Position crank weight contacts SST.)

3. Install the SST to the crankshaft pulley and lock the crankshaft against rotation.

am6zzw00007186

No.3 Engine Mount Rubber, No.3 Engine Joint Bracket Removal Note

1. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

2. Install the SST using the following procedure.

  Caution
  • Refer to the SST instruction manual for the basic handing procedure.

  am6zzw00007187

  (1) Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.

  am6zzw00007188

    Caution
    • When setting the SST on the right side, make sure it doesn’t interfere with the DSC HU/CM.

  (2) Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)

  (3) Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.

  am6zzw00007189

  (4) Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.

  (5) Make sure each joint is securely tightened.

3. Support the engine using the SST.

am6zzw00007190

  Note
  • The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).

Engine Front Cover Removal Note

1. Remove the front oil seal using a flathead screwdriver or similar tool.

am6zzw00007191

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.

am6zzw00007192

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

am6zzw00007193

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

am6zzw00007194

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

am6zzw00007195

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.

am3zzw00004319

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.

am6zzw00007196

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.

am3uuw00001568

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, 14.8—22.1 ft·lbf}

Timing Chain Installation Note

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

am6zzw00007197

2. Install the timing chain.

3. Remove the wire or paper clip from the chain tensioner piston and apply tension to the timing chain.

Front Oil Seal Installation Note

1. Apply clean engine oil to a new front oil seal.

2. Push the front oil seal in the engine front cover by hand.

3. Use the SST to tap in the front oil seal.

am6zzw00007198

am6zzw00007199

  Front oil seal press-in amount

  0—0.5 mm {0—0.019 in}

Engine Front Cover Installation Note

1. Apply silicone sealant to the engine front cover.

  Caution
  • Install the engine front cover within 10 min of applying the silicone sealant.

am6zzw00007200

  Thickness

  A: 2.2—3.2 mm {0.086—0.126 in}

  B: 1.5—2.5 mm {0.059—0.098 in}

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

am6zzw00007201

Installation Position | Tightening Torque N·m {kgf·m, ft·lbf}
1—18 | 8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf}
19—22 | 40—55 {4.1—5.6, 29.7—40.5}

No.3 Engine Mount Rubber, No.3 Engine Joint Bracket Installation Note

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

am6zzw00007202

  Tightening torque

  7.0—13 N·m {71.4—132.5 kgf·cm, 62.0—115.0 in·lbf}

2. Temporarily tighten the No.3 engine mount rubber installation bolts.

3. Install the No.3 engine joint bracket and tighten the bolts and nuts in the order shown in the figure.

am6zzw00007203

Crankshaft Pulley Lock Bolt Installation Note

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

am6zzw00007197

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

3. To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0 length 25—35 mm {0.99—1.37 in}), fix the crankshaft pulley to the engine front cover.

am6zzw00007204

4. Install the SSTs to the crankshaft pulley, lock the crankshaft against rotation, and tighten the crankshaft pulley lock bolt using the following two steps.

am6zzw00007186

  Tightening procedure

  (1) 96—104 N·m {9.8—10.6 kgf·m, 70.9—76.7 ft·lbf}
  (2) 87°—93°

5. Remove the bolt (M6 X 1.0 length 25—35 mm {0.99—1.37 in}) installed to the crankshaft pulley.

6. Remove the SST from the camshaft.

7. Remove the SST installed in the cylinder block lower blind plug hole.

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

  • If not aligned, repeat from Step 1.

9. Install the cylinder block lower blind plug.

am6zzw00007205

  Tightening torque

  18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}

Cylinder Head Cover Installation Note

1. Apply silicone sealant to the areas shown in the figure.

am6zzw00007206

am6zzw00007207

  Thickness

  5.0 mm {0.196 in}

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

am6zzw00007208

  Tightening torque

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