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 injuries 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 front wheel and tire (RH).

3.  Remove the splash shield (RH).

4.  Loosen the water pump pulley bolt and removal the drive belt. (See DRIVE BELT REPLACEMENT [L3].)

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

6.  Disconnect the high tension leads from the spark plugs. (R.H.D. model)

7.  Remove the ignition coil. (L.H.D. model)

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 in the order indicated in the table.

10.  Install in the reverse order of removal.

11.  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.

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1	Cylinder head cover (See Cylinder Head Cover Installation Note.) [L3].)
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 Engine Front Cover 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	Camshaft 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 the crankshaft is in the No.1 cylinder TDC position.

4.  Hold the crankshaft pulley using the SSTs.

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Chain Tensioner Removal Note

1.  Hold the chain tensioner ratchet lock mechanism away from the ratchet stem using a thin screwdriver.

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

1.  Suspend the engine using the SSTs.

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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.

Engine Front Cover Removal Note

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

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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.

European countries

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Except European countries

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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

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

Caution

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

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2.  Install the cylinder head cover bolts in the order as shown.

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Bolt No.	Tightening torque (N·m {kgf·m, ft·lbf})
1—18	8.0—11.5 {81.6—117.2, 70.9—101.7}
19—22	40—55 {4.1—5.6, 29.7—40.5}

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.

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2.  Hand-tighten the No.3 engine mount rubber and No.3 engine joint bracket.

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

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Crankshaft Pulley Lock Bolt Installation Note

1.  Install the SST to the camshaft as shown.

European countries

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Except European countries

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2.  Verify that cylinder No.1 is at TDC of the compression stroke. (Position counterweight contacts 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.

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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, 70.9—76.7 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.

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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 min of applying the silicone sealant.

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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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