TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.6]

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Warning
•  Do not remove the jack from the engine with the bolt of engine mount No. 3 removed because the engine may fall off and cause a serious accident.

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.6].)

2.  Remove the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION).)

3.  Remove the front under cover No.2 and splash shield. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.6].)

5.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.6].)

6.  Set the wiring harness aside.

7.  Set the cooler pipe and the cooler hose aside. (With A/C) (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZR 1.6].)

8.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.6].)

9.  Disconnect the crankshaft position (CKP) sensor connector.

10.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR 1.6].)

11.  Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION [MZR 1.6].)

12.  Remove in the order indicated in the table.

13.  Install in the reverse order of removal.

14.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.6].)

15.  Start the engine, and inspect the following and adjust them if necessary.

(1)  Leakage of engine oil and engine coolant.
(2)  Pulley and belt for runout and contact
(3)  Ignition timing and idle speed. Verify the amount of CO and HC. (See ENGINE TUNE-UP [MZR 1.6].)

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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
Drive belt auto tensioner
5
Idler
6
Dipstick pipe
7
No.3 engine mount
(See No.3 Engine Mount Removal Note.)
(See No.3 Engine Mount Installation Note.)
8
OCV
9
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [MZR 1.6].)
10
Engine front cover
(See Engine Front Cover Installation Note.)
11
Chain tensioner
(See Chain Tensioner Removal Note.)
12
Chain tensioner arm
13
Chain guide
14
Timing chain
(See Timing Chain Removal Note.)
(See Timing Chain Installation Note.)
15
Crankshaft sprocket
16
Key


Crankshaft Pulley Lock Bolt Removal Note

Caution
•  To prevent damaging the crankshaft pulley, protect the crankshaft pulley with a clean rag so that the SST and the crankshaft pulley do not come into contact each other.

1.  Fix the crankshaft pulley using the SSTs, and remove the crankshaft pulley lock bolt.

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No.3 Engine Mount Removal Note

1.  Remove the clips shown in the figure and set the ground cable aside.

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Caution
•  When supporting the housing, verify that any switches and wiring harnesses are not caught.

2.  Support the engine using the following procedures.

When using a garage jack
•  Support the clutch housing (MTX) or the converter housing (ATX) using a garage jack with a wood slab of appropriate size inserted to secure the housing.
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When using a engine lifter
•  Support the engine using an engine lifter.
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Caution
•  Slots have been adopted for the No.3 engine mount installation holes. If the No.3 engine mount is deviated from the original position when installing the No.3 engine mount, engine noise or vibration could increase. Before removing the No.3 engine mount, place alignment marks on the No.3 engine mount and body so that they can be assembled to the same positions as before removal.

3.  Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.

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Note
•  Paint so that the No.3 engine mount is framed on the body side and the outline of the nut is framed on the No.3 engine mount side.

4.  Remove the No. 3 engine mount.


Chain Tensioner Removal Note

1.  Push down the link plate of the timing chain tensioner using a thin flathead screwdriver (precision screwdriver), and release the plunger lock.

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2.  Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.

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3.  Free the link plate with the plunger still pressed down.

4.  Release the pressure slightly from the plunger, and move the plunger back and forth 2—3 mm{0.08—0.11 in}.

5.  Insert an approx. 1.5 mm {0.06 in} wire or the paper clip where the link plate hole and the tensioner body hole overlap to fix the link plate and lock the plunger.

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Timing Chain Removal Note

1.  Rotate the crankshaft clockwise and align the key groove of the crankshaft sprocket to the timing mark, and then position the No.1 cylinder to TDC.

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2.  Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

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3.  Remove the timing chain.


Timing Chain Installation Note

1.  Align the key groove of the crankshaft sprocket to the timing mark, and then position the No.1 cylinder to TDC.

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2.  Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

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3.  Install the timing chain.

4.  After installing the chain adjuster, remove the wire or the paper clip installed to the chain tensioner, and apply tension to the timing chain. (Remove the installed stopper when installing the new chain tensioner.)

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5.  Verify that there is no slack on the timing chain, and then verify that each sprocket is positioned in the proper place again.

6.  Rotate the crankshaft clockwise twice, and then inspect the valve timing.


Engine Front Cover Installation Note

Caution
•  Install the engine front cover before the applied silicone sealant starts to harden.

1.  Apply the silicon sealant to the engine front cover as shown in the figure.

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Thickness
2—4 mm {0.08—0.15 in}

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

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Bolt number

Tightening torque
1—6, 8, 10,
12—15, 17, 18
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
7, 11, 16
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}
9
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


No.3 Engine Mount Installation Note

Caution
•  If the No.3 engine mount is deviated from the original position when installing the No.3 engine mount, engine noise or vibration could increase. When installing the No.3 engine mount, align the alignment mark placed during removal and install it to the original position.
Note
•  When replacing the No.3 engine mount, place a mark at the same position as the one placed before removal.
•  If the No.3 engine mount nut is loosened, tighten the engine front cover stud bolts because they may have loosened.

1.  Tighten the stud bolts of the engine front cover.

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2.  Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:

(1)  Align the alignment marks on the body side and No.3 engine mount, and temporarily tighten the bolts shown in the figure.
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(2)  Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 engine mount and nuts.
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Note
•  If the alignment marks are not aligned, align the alignment marks while slightly moving the engine and temporarily tighten the nuts.

3.  Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.

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Tightening torque

Installation position

Tightening torque
1
76—95 N·m {7.8—9.6 kgf·m, 57—70 ft·lbf}
2
55—65 N·m {5.7—6.6 kgf·m, 41—47 ft·lbf}
3
49—65 N·m {5.0—6.6 kgf·m, 37—47 ft·lbf}

4.  Remove the engine lifter or garage jack.

5.  Install the clips of the ground cable.

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Crankshaft Pulley Lock Bolt Installation Note

Caution
•  To prevent damaging the crankshaft pulley, protect the crankshaft pulley with a clean rag so that the SST and the crankshaft pulley do not come into contact each other.

1.  Fix the crankshaft pulley using the SSTs.

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2.  Tighten the crankshaft pulley lock bolt.

Tightening torque
157—167 N·m {16.1—17 kgf·m, 116—123 ft·lbf}


Cylinder Head Cover Installation Note

1.  Apply silicon sealant as shown in the figure.

Caution
•  Install the cylinder head cover before the applied silicone sealant starts to harden.
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Thickness
2—6 mm {0.08—0.23 in}
Length
6—26 mm {0.24—1.02 in}

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

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Tightening torque
7—10 N·m {72—101 kgf·cm, 62—88 in·lbf}