TIMING CHAIN REMOVAL/INSTALLATION [L3]

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Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [L3].)

1.  Disconnect the negative battery cable.

2.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [L3])

3.  Remove the tire (RH).

4.  Remove the under cover.

5.  Loosen the water pump pulley bolt and removal the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [L3].)

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

7.  Drain the engine oil. (See ENGINE OIL REPLACEMENT [L3].)

8.  Remove the P/S oil pump with the oil hose still connected and position the P/S oil pump so that it is out of the way. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L3].)

9.  Remove the front drive shaft (RH) from the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [L3].)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Start the engine and:

•  Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.

•  Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [L3].)

13.  Perform a road test.

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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	Water pump pulley
5	Drive belt idler pulley
6	No.3 engine mount rubber and No.3 engine joint bracket (See No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Removal Note) (See No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Installation Note)
7	Engine front cover (See Engine Front Cover Installation Note)
8	Front oil seal (See Front Oil Seal Removal Note) (See Front Oil Seal Installation Note)
9	Chain tensioner (See Chain Tensioner Removal Note)
10	Tensioner arm
11	Chain guide
12	Timing chain (See Timing Chain Installation Note)
13	Oil pump chain tensioner
14	Oil pump chain guide
15	Oil pump sprocket (See Oil Pump Sprocket Removal Note) (See Oil Pump Sprocket Installation Note)
16	Oil pump chain
17	Crankshaft sprocket

Crankshaft Pulley Lock Bolt Removal Note

1.  Remove the cylinder block lower blind plug.

2.  Install the SST.

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3.  Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST).

4.  Hold the crankshaft pulley by using the SSTs.

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

1.  Install the SST using the following procedure.

Caution

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

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

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(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.

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(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.

2.  Support the engine using the SST.

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Note

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

Front Oil Seal Removal Note

1.  Remove the oil seal using a screwdriver as shown.

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Chain Tensioner Removal Note

1.  Using a thin screwdriver, hold the chain tensioner ratchet lock mechanism away from the ratchet stem.

2.  Slowly compress the tensioner piston.

3.  Hold the tensioner piston using a 1.5 mm {0.059 in} wire or paper clip.

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Oil Pump 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 sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Oil Pump 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 sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Timing Chain Installation Note

1.  Install the SST to the camshaft as shown.

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2.  Install the timing chain.

3.  Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain.

Engine Front Cover Installation Note

Caution

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

1.  Apply silicone sealant to the engine front cover as shown.

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2.  Install the engine front cover bolts in the order as shown.

Bolt No.	Tightening torque
1—18	8.0—11.5 N·m {82—107 kgf·cm, 71—92 in·lbf}
19—22	40—55 N·m {4.1—5.6 kgf·m, 30—40 ft·lbf}

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Front Oil Seal Installation Note

1.  Apply clean engine oil to the oil seal.

2.  Push the oil seal slightly in by hand.

3.  Compress the oil seal using the SST and a hammer.

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

1.  Tighten the stud bolt of the No.3 engine mount bracket.

Tightening torque:

7.0—13.0 N·m {71.4—132 kgf·cm, 62.0—115 in·lbf}

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2.  Install the No.3 engine mount rubber hand-tighten.

3.  Tighten the No.3 engine joint bracket is attached and bolts, nuts in the order as shown.

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Crankshaft Pulley Lock Bolt Installation Note

1.  Install the SST to the camshaft as shown.

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2.  Install the M6 x 1.0 bolt in by hand.

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3.  Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST)

4.  Hold the crankshaft pulley using the SST.

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5.  Tighten the crankshaft pulley lock bolt using the following two steps.

(1)  Tighten to 96—104 N·m {9.8—10.6 kgf·m, 71—76 ft·lbf}

(2)  Tighten 87°—93°

6.  Remove the M6 x 1.0 bolt.

7.  Remove the SST from the camshaft.

8.  Remove the SST from the cylinder block lower blind plug.

9.  Rotate the crankshaft clockwise two turns until the TDC position.

•  If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

10.  Install the cylinder block lower blind plug.

Tightening torque:

18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}

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Cylinder Head Cover Installation Note

1.  Apply silicone sealant to the mating faces as shown.

Caution

•  Install the cylinder head cover within 10 minutes of applying the silicone sealant.

Thickness:

4.0—6.0 mm {0.16—0.23 in}

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2.  Install the cylinder head cover with a new gasket.

3.  Tighten the bolts in the order shown.

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