Exploded View

1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH) 4. Camshaft sprocket (INT) 5. Plug 6. Front oil seal 7. Crankshaft pulley
8. Crankshaft pulley bolt 9. Front cover
10. Crankshaft sprocket 11. Crankshaft sprocket key 12. Oil pump sprocket
13. Oil pump drive chain 14. Oil pump drive chain tensioner 15. Timing chain
16. Timing chain tension guide

A.Tightening must be done following the installation procedure.

Refer to EM-182

: Always replace after every
disassembly.

: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Sealing point
: Should be lubricated with oil.

Removal and Installation

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

REMOVAL

1. Remove front road wheel (RH).

2. Remove front fender protector (RH). Refer to EXT-22, "Exploded View".

3. Drain engine oil. Refer to LU-26, "Draining".

NOTE

:
Perform this step when engine is cold.

4. Remove the following parts.

• Rocker cover: Refer to EM-178, "Exploded View".

• Drive belt: Refer to EM-155, "Removal and Installation".

• Water pump pulley: Refer to CO-22, "Exploded View".

5. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to EM-215, "Exploded View".

6. 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. Check the matching marks on each camshaft sprocket are positioned as shown in the figure.

1 : Timing chain
2 : Camshaft sprocket (EXH) 3. : Camshaft sprocket (INT) A : Matching mark (Peripheral knurls) B : Matching mark (stamp) C : Matching mark (Peripheral groove)

• If not, rotate crankshaft pulley one more turn to align matching marks to the positions in the figure.

7. Remove crankshaft pulley with the following procedure: a. Secure crankshaft pulley (1) using a pulley holder (commercial service tool) (A).

b. Loosen and pull out crankshaft pulley bolts.

CAUTION:
Never remove the mounting bolts as they will be used as a supporting point for the pulley puller [SST: KV11103000].

c. Attach a pulley puller [SST: KV11103000] (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley.

B : M6 bolt

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

b. Cut liquid gasket by prying the position (
) as shown in the figure, and then remove the front cover.

9. 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.

10. 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.

• Figure shows the example that a hexagonal wrench for 2.5 mm (0.098 in) is used.

d. Remove chain tensioner.

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

12. Remove the timing chain (2).

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

CAUTION:
Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.

13. 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 nuts and remove them.

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 figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.

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

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.

: Engine front

• Install the crankshaft sprocket so that its invalid gear area (A) is towards the back of the engine.

• Install the oil pump sprocket 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.

• Check that the tension is applied to the oil pump drive chain after installing.

2. Install timing chain with the following procedure.

A : Matching mark (Peripheral groove) B : Pink link
C : Matching mark (Peripheral knurls) D : Orange link
E : Matching mark (stamp) F : Crankshaft key (point straight up)

• 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:
• For the following note, after the matching marks are aligned, keep them aligned by holding them with a hand.

• To avoid skipped teeth, never rotate crankshaft and camshaft until front cover is installe

d.

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

4. Install chain tensioner (1).

• Fix the plunger at the most compressed position using a stopper pin (A), and then install it.

• Securely 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 EM-206, "FRONT OIL SEAL : Removal and Installation" 7. Install front cover with the following procedure: a. Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to front cover as shown in the figure.

Use Genuine Liquid Gasket or equivalent.

1 : Cylinder head
2 : Cylinder block
3 : Oil pan (upper)
A : Liquid gasket application area [φ3.0 - 4.0 mm (0.12 - 0.16 in)]

b. Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to front cover as shown in the figure.

Use Genuine Liquid Gasket or equivalent.

1 : Front cover edge
A : Liquid gasket application area b : 4.0 - 5.6 mm
c : Liquid gasket application area [φ3.0 - 4.0 mm (0.12 - 0.16 in)]

c. Tighten bolts in the numerical order as shown in the figure.

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

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:
Install protecting front oil seal lip section from any damage.

9. Tighten crankshaft pulley bolt with the following procedure: • Secure crankshaft pulley with a pulley holder (commercial service 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.

: 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. Check that crankshaft turns smoothly by rotating by hand clockwise.

11. Install in the reverse order of removal.

Inspection

INSPECTION AFTER REMOVAL

Timing Chain
Check for cracks (A) and any excessive wear (B) at link plates and roller links of timing chain. Replace timing chain if necessary.

INSPECTION AFTER INSTALLATION

Inspection for Leakage The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-13, "Fluids and Lubricants".

• Use procedure below to check for fuel leakage.

- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.

- Start engine. With engine speed increased, check again for fuel leakage at connection points.

• Run engine to check for unusual noise and vibration.

NOTE

:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.

• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.

• Bleed air from lines and hoses of applicable lines, such as in cooling system.

• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.