TIMING CHAIN REMOVAL/INSTALLATION [LF]

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 Fuel Line Safety Procedure.)

1. Remove the following parts.

(1) Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF].)

(2) Plug hole plate bracket

(3) Accelerator cable and bracket

(4) Battery cover (See BATTERY REMOVAL/INSTALLATION [LF].)

2. Disconnect the negative battery cable.

3. Remove the following parts.

(1) Ignition coils (See IGNITION COIL REMOVAL/INSTALLATION [LF].)

(2) Front wheel and tire (RH) (See GENERAL PROCEDURES (SUSPENSION).)

(3) Under cover and splash shields

(4) Crankshaft position (CKP) sensor (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [LF].)

(5) Drive belt (See DRIVE BELT REPLACEMENT [LF].)

(6) A/C compressor with the oil hose still connected and position the A/C compressor so that it is out of the way (See A/C COMPRESSOR REMOVAL/INSTALLATION [LF].)

(7) Coolant reserve tank with the hose still connected and position the coolant reserve tank so that it is out of the way

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

6. Start the engine.

7. Inspect the following and adjust if necessary.

• Pulley and belt for runout and contact

• Leakage of engine oil

• Ignition timing and idle speed, and amount of CO and HC (See ENGINE TUNE-UP [LF].)

• Engine-driven accessories operation

.

Crankshaft Pulley Lock Bolt Removal Note

1. Remove the cylinder block lower blind plug.

2. Install the SST.

3. Turn the crankshaft clockwise 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 SSTs.

No.3 Engine Mount Rubber Removal Note

1. Install the suitable wood slabs between the front fender panel and apron reinforcement upper.

Note

• Wood slab height

4SD: approx. 35 mm {1.38 in}

5HB: approx. 60 mm {2.36 in}

• Cut the wood slab into two piece and insert.

2. Support the engine using the SST.

Note

• A hoist or small crane can be used in place of the SST (49E 017 5A0).

Engine Front Cover Removal Note

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

Chain Tensioner Removal Note

1. Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool.

2. Slowly compress the tensioner piston.

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

Oil Pump Sprocket Removal Note

1. Hold the oil pump sprocket using the SST.

Oil Pump Sprocket Installation Note

1. Hold the oil pump sprocket using the SST.

Timing Chain Installation Note

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

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 in the figure.

Caution

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

Thickness

A: 2.2-3.2 mm {0.087-0.125 in}

B: 1.5-2.5 mm {0.059-0.098 in}

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

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.

No.3 Engine Mount Rubber Installation Note

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

Tightening torque

7.0-13 N·m

{71.4-132.5 kgf·cm, 62.0-115.0 in·lbf}

Note

• If the No.3 engine mount bracket and the engine are removed, retighten the No.3 engine mount bracket stud bolt

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

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

Crankshaft Pulley Lock Bolt Installation Note

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

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

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.

5. Tighten the crankshaft pulley lock bolt in the order shown with the following 2 steps using the SST (49 D032 316).

Tightening torque

(1) 96-104 N·m

{9.8-10.6 kgf·m, 70.9-76.7 ft·lbf}

(2) 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}

Cylinder Head Cover Installation Note

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

Caution

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

•  Thickness

4.0-6.0 mm {0.16-0.23 in}

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

3. Tighten the bolts in the order shown in the figure.

Tightening torque

8.0-10.5 N·m

{81.6-107.1 kgf·cm, 70.9-94.4 in·lbf}