Part 1

Removal

1. Remove the cylinder head assembly.
2. Remove the alternator (A).




3. Remove the alternator bracket (A).




4. Remove the air conditioner compressor (A).




5. Remove the drive belt idler (A).




6. Remove the water pump pulley (A).




7. Remove the drive belt tensioner (A).




8. Remove the oil filter & cooler assembly (B).




9. Remove the lower oil pan(A).
Insert the blade of SST(09215-3C000) between the upper oil pan and the lower oil pan. Cut off applied sealer and remove the lower oil pan.





NOTE:
- Insert the SST between the lower oil pan and the upper oil pan by tapping it with a plastic hammer in the direction of (1) arrow.
- After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the lower oil pan, remove it from the lower oil pan.
- Do not use the SST as a prybar. Hold the tool in position (on the gasket line) and tap in with a light hammer.
- Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.

10. Remove the upper oil pan (A).
Insert the blade of SST(09215-3C000) between the upper oil pan and the cylinder block. Cut off applied sealer and remove upper oil pan.





NOTE:
- Insert the SST between the upper oil pan and the cylinder block by tapping it with a plastic hammer in the direction of (1) arrow.
- After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the upper oil pan, remove it from the upper oil pan.
- Do not use the SST as a prybar. Hold the tool in position (on the gasket line) and tap in with a light hammer.
- Be careful not to damage the contact surfaces of Upper oil pan and cylinder block.

11. Remove the crankshaft pulley (A).





NOTE:
Use the SST(flywheel stopper, 09231-2B100) to remove the crankshaft pulley bolt, after remove the starter.




12. Remove the front oil seal (A).




13. Remove the water pump (A).




14. Remove the water temperature control assembly (A).




15. Remove the O-ring from the water temperature control assembly (A).




16. Remove the timing chain lower cover (A).

[Front]





[Rear]




17. Remove the O-ring from the timing chain cover (A).




18. Remove the timing chain tensioner arm (A) and the timing chain guide (B) and then remove the timing chain.








19. Insert a set pin after compressing the oil pump chain tensioner (A) and then remove the oil pump sprocket (B) and chain (C).




20. Remove the crankshaft sprocket (A) and friction plates (B).




21. Remove the tensioner adapter (A) and the timing chain guide bolts (B).






Inspection

Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

Installation

1. Install the tensioner adapter (A) and the timing chain guide bolts (B).

Tightening torque :
Tensioner adapter bolts:
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain guide bolts :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)




2. Install the crankshaft sprocket (A) with the friction plates (B).

NOTE:
Completely fix the four friction plate clips and the sprocket groove.
Align the key-home of the friction plate with the key-home of the sprocket.
Be careful for the clip not to be folded.
The block is placed at bottom up before install the timing chain system and timing chain cover assembly.





CAUTION:
The mark of friction plate should be placed top. (Engine is placed bottom up)

3. Install the oil pump chain (C) with the oil pump sprocket (B) and oil pump chain tensioner (A).

Tightening torque :
A : 9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
B : 21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)




4. Install the timing chain with the timing chain tensioner arm (A) , the timing chain guide (B) and the timing chain locking tool (SST : 09231-2J600) (C).

Tightening torque :
Timing chain tensioner arm bolts :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)









NOTE:
Align the timing mark of the friction plate and crankshaft sprocket.




5. Install the timing chain lower cover (A).

NOTE:
Assemble the timing chain lower cover with engine bottom up condition.

(1) The sealant locations on chain lower cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
(2) Install the new gasket (A) to the timing chain lower cover.




(3) Apply liquid sealant LT 5900H or equivalent on timing chain lower cover. The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied in a continuous need in each of the areas indicated below.

Bead width :Ø2.5 ± 0.5mm









NOTE:
- During timing chain lower cover installation, care not to take off applied sealant on the timing chain lower cover by contact with other parts.
- Apply sealant in a 4.0 ± 0.5mm wide spot for the 4 T-joints (D).

(4) The dowel pins on the cylinder block and holes on the timing chain lower cover should be used as a reference in order to assemble the timing chain lower cover to be in exact position.

Tightening torque :
23.5 - 27.5N.m (2.4 - 2.8kgf.m, 17.4 - 20.3lb-ft)

[Front]





[Rear]




(5) Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
6. Install the cylinder head assembly.

NOTE:
Before install the cylinder head assembly, place the engine up right.

7. Install the camshaft assembly.
8. Remove the SST from the timing chain guide and the timing chain tensioner arm.
9. Install the timing chain to the camshaft sprocket.