Removal and Installation

TIMING CHAIN


Removal and Installation


CAUTION:
The rotation direction indicated in the text indicates all directions seen from the engine front.

REMOVAL
1. Remove front wheel (RH). Refer to Rotation.
2. Remove front fender protector (RH). Refer to Removal and Installation.
3. Drain engine oil. Refer to Draining.

CAUTION:
Perform this step when engine is cold.
4. Remove the following parts.
- Intake manifold: Refer to Exploded View.
- Drive belt: Refer to Service and Repair.
- Water pump pulley: Refer to Exploded View.
- Ground cable (RH)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to Exploded View.
6. Remove rocker cover. Refer to Exploded View.
7. Set No. 1 cylinder at TDC of its compression stroke with the following procedure:





a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.

B : White paint mark (Not use for service)






b. Make sure the matching marks on each camshaft sprocket are positioned as shown.

1 : Camshaft sprocket (EXH)
2 : Camshaft sprocket (INT)
A : Matching mark (stamp)
B : Matching mark (peripheral stamp line)

- If not, rotate crankshaft pulley one more turn to align matching marks to the positions.
8. Remove crankshaft pulley with the following procedure:





a. Secure crankshaft pulley (1) using a suitable tool (A).
b. Loosen and pull out crankshaft pulley bolts.

CAUTION:
Never remove the bolts as they are used as a supporting point for the pulley puller.





c. Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley.

B : M6 bolt


Tool number : KV11103000 ( - )

9. Remove front cover with the following procedure:
a. Loosen bolts in the reverse of the order shown.





b. Cut liquid gasket by prying the position shown, and then remove the front cover.
10. Remove front oil seal from front cover.





- Remove by lifting it up using a suitable tool.

CAUTION:
Be careful not to damage the front cover.





11. Remove chain tensioner (1) with the following procedure.
a. Fully push down the chain tensioner lever (A), and then push the plunger (C) into the inside of tensioner.
- The tab (B) is released by fully pushing the lever down. As a result, the plunger can be moved.
b. Pull up the lever to align its hole position with the body hole position.
- When the lever hole is aligned with the body hole position, the plunger is fixed.
- When the protrusion parts of the plunger ratchet and the tab face each other, both hole positions are not aligned. At that time, correctly engage them and align these hole positions by slightly moving the plunger.
c. Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper position.
- The example that a hexagonal wrench for 2.5 mm (0.098 in) is used as shown.
d. Remove chain tensioner.





12. Remove the timing chain tension guide (2) and the timing chain slack guide (1).
13. Remove the timing chain (2).





- Pull the looseness of timing chain toward the camshaft sprocket (EXH) (1), and then remove the timing chain (2) and start the removal from camshaft sprocket (EXH) (1) side.

CAUTION:
Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.
14. Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure.





a. Remove chain tensioner (1).
- Pull out from the shaft (B) and spring fixing holes (A).





b. Hold the top of the oil pump shaft using the TORX socket (size: E8), and then loosen the oil pump sprocket nut and remove it.
c. Remove the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time.

INSTALLATION

NOTE:
The illustration shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.

1 : Timing chain
2 : Camshaft sprocket (EXH)
3 : Timing chain slack guide
4 : Chain tensioner
5 : Oil pump drive chain
6 : Oil pump sprocket
7 : Crankshaft sprocket
8 : Timing chain tension guide
9 : Camshaft sprocket (INT)
A : Dark blue link
B : Matching mark (stamp)
C : Orange link
D : Matching mark (stamp)
E : Crankshaft key (point straight up)
F : Matching mark (peripheral stamp line)
G : Dark blue link






1. Install the crankshaft sprocket and the oil pump drive related parts with the following procedure:
a. Install the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time.






Arrow Indicates Engine front

- Install the crankshaft sprocket (1) so that its invalid gear area (A) is towards the back of the engine.
- Install the oil pump sprocket (3) so that its hexagonal surface faces (B) the front of engine.

NOTE:
There is no matching mark in the oil pump drive related parts.





b. Hold the top of the oil pump shaft using the TORX socket (size: E8), and then tighten the oil pump sprocket nuts.

1 : Crankshaft sprocket
2 : Oil pump drive chain
3 : Oil pump sprocket






c. Install chain tensioner (1).
- Insert the body into the shaft (B) while inserting the spring into the fixing hole (A) of cylinder block front surface.
- Make sure that the tension is applied to the oil pump drive chain after installing.
2. Install timing chain with the following procedure.

A : Dark blue link
B : Matching mark (stamp)
C : Orange link
D : Matching mark (stamp)
E : Crankshaft key (point straight up)
F : Matching mark (peripheral stamp line)
G : Dark blue link

- Install by aligning matching marks on each sprocket and timing chain.





- If these matching marks are not aligned, rotate the camshaft slightly to correct the position.

CAUTION:
- Check matching mark position of each sprocket and timing chain again after installing the timing chain, keep matching marks aligned by holding them with a hand.
- To avoid skipped teeth, never rotate crankshaft and camshaft until front cover is installed.





3. Install timing chain tension guide (2) and timing chain slack guide (1).
4. Install chain tensioner (1).





- Secure the plunger at the most compressed position using a stopper pin (A), and then install it.
- Pull out the stopper pin after installing the chain tensioner.
5. Check matching mark position of timing chain and each sprocket again.
6. Install the front oil seal to the front cover. Refer to Service and Repair
7. Install front cover with the following procedure:
a. Apply a continuous bead of liquid gasket with Tool to front cover as shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to Fluid Type Specifications.

1 : Cylinder head
2 : Cylinder block
3 : Oil pan (upper)
A : Liquid gasket application dia 3.0 - 4.0 mm (0.12 - 0.16 in) dia.

Tool number : WS39930000 ( - )






b. Apply a continuous bead of liquid gasket with Tool to front cover as shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to Fluid Type Specifications.

A : Liquid gasket application dia 3.0 - 4.0 mm (0.12 - 0.16 in) dia.


Tool number : WS39930000 ( - )






c. Tighten bolts in the numerical order shown.
d. After all bolts are tightened, retighten them to specified torque in numerical order as shown.

CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to surface.





8. Insert crankshaft pulley by aligning with crankshaft key.
- When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).

CAUTION:
Never damage front oil seal lip section.
9. Tighten crankshaft pulley bolt with the following procedure:
- Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.

Crankshaft pulley bolt : 35.0 N.m (3.6 kg-m, 26 ft-lb)






c. Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange (1).
d. Turn another 60 degrees clockwise (angle tightening).
- Check the tightening angle with movement of one angle mark.
10. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
11. Installation of the remaining components is in the reverse order of removal.