Timing Chain: Service and Repair

TIMING CHAIN

COMPONENTS

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4) (for Hatchback):

COMPONENTS (Part 5) (for Sedan):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER RH
4. DRAIN ENGINE OIL
5. DRAIN ENGINE COOLANT
6. REMOVE CYLINDER HEAD COVER NO. 2
7. REMOVE FAN AND GENERATOR V BELT
8. REMOVE GENERATOR ASSEMBLY
9. REMOVE IGNITION COIL NO. 1
10. DISCONNECT VENTILATION HOSE
11. DISCONNECT VENTILATION HOSE NO. 2
12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
13. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
14. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY
15. REMOVE CRANKSHAFT POSITION SENSOR
16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
17. REMOVE WATER PUMP PULLEY
18. REMOVE WATER PUMP ASSEMBLY
19. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
20. REMOVE OIL PUMP ASSEMBLY
21. REMOVE OIL PUMP SEAL
22. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1

NOTICE:
^ Do not rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

(a) Pull up the stopper plate and hold it with its lock released.

(b) Unlock the plunger of the tensioner and push it in to the end.

(d) Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

(e) Remove the 2 bolts and remove chain tensioner assembly No. 1.

23. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.

24. REMOVE CHAIN VIBRATION DAMPER NO. 1
(a) Remove the 2 bolts and remove chain vibration damper No. 1.

25. REMOVE CHAIN SUB-ASSEMBLY

INSPECTION

1. INSPECT CHAIN SUB-ASSEMBLY
(a) Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb) to the timing chain and measure its length.
Maximum chain elongation: 123.2 mm (4.850 in.)

If the elongation is greater than the maximum, replace the chain.

HINT: Perform the same measurement at 3 or more random places and calculate the average length.

INSTALLATION

TDC:

1. INSTALL CHAIN SUB-ASSEMBLY
(a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration.

HINT: The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring.

(b) Set the timing mark of the crankshaft in a position between 40 and 140°ATDC as illustrated.

20 Degress ATDC:

(c) Set the camshaft timing gear and the camshaft timing sprocket in the positions (20° ATDC) shown in the illustration.
(d) Set the crankshaft in the position (20° ATDC) shown in the illustration.

(e) Install chain vibration damper No. 1 with the 2 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

(f) Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.

HINT: Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench.

2. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.

3. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
(a) Install chain tensioner assembly No. 1 with the 2 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(b) Remove the bar from chain tensioner assembly No. 1.

4. INSTALL OIL PUMP SEAL
5. INSTALL OIL PUMP ASSEMBLY
6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
7. INSTALL WATER PUMP ASSEMBLY
8. INSTALL WATER PUMP PULLEY
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
10. INSTALL CRANKSHAFT POSITION SENSOR
11. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
12. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
14. CONNECT VENTILATION HOSE NO. 2
15. CONNECT VENTILATION HOSE
16. INSTALL IGNITION COIL NO. 1
17. INSTALL GENERATOR ASSEMBLY
18. INSTALL FAN AND GENERATOR V BELT
19. ADJUST FAN AND GENERATOR V BELT
20. INSPECT FAN AND GENERATOR V BELT
21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

22. ADD ENGINE OIL
23. ADD ENGINE COOLANT
24. CHECK ENGINE OIL LEVEL
25. CHECK FOR ENGINE OIL LEAKAGE
26. CHECK FOR ENGINE COOLANT LEAKAGE
27. INSTALL CYLINDER HEAD COVER NO. 2
28. INSTALL ENGINE UNDER COVER RH
29. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)