Contents: Removal the right engine mount…↓ Removal the ignition coil ↓ Removal the cylinder head cover ↓ Removal the poly V-belt tensioner…↓ Removal the right engine mount…↓ Setting the piston of cylinder No.1…↓ Removal the crankshaft pulley ↓ Removal chain tensioner #1 ↓ Removal the timing chain or belt…↓ Removal the timing chain or belt…↓ Removal the toothed disk of the…↓ Removal the chain tensioner shoe ↓ Removal the chain assembly ↓ Installing the chain assembly ↓ Installing the timing chain or belt…↓ Installing the timing chain or belt…↓ Installing the chain tensioner…↓ Installing the crankshaft pulley ↓ Installing the crankshaft position…↓ Installing the cylinder head cover ↓
Fig. 2.121. Timing chain components
The components of the timing chain are shown in Fig. 2.121.
Removal the right engine mount cushion
Fig. 2.122. Fuel return pipe bracket mounting bolt
Remove the bolt, then disconnect the fuel return line (fig. 2.122).
Fig. 2.123. Oil tank bracket mounting bolts No.1
Remove 2 bolts, then disconnect oil tank bracket #1 (fig. 2.123).
Place a wooden block on the jack and move the jack under the engine.
Fig. 2.124. Bolts and nuts for fastening the right engine mount cushion
Remove 4 bolts and 2 nuts, then remove the right engine mount cushion (fig. 2.124).
Removal the ignition coil
Fig. 2.125. Ignition coil connectors
Disconnect 4 ignition coil connectors (fig. 2.125).
Fig. 2.126. Engine wiring harness mounting nuts
Remove the 2 nuts, then remove the engine wiring harness (fig. 2.126).
Fig. 2.127. Ignition coil mounting bolts
Remove 4 bolts, then remove 4 ignition coils (fig. 2.127).
Removal the cylinder head cover
Fig. 2.128. Crankcase ventilation hose
Disconnect the crankcase ventilation hose from the cylinder head cover (fig. 2.128).
Fig. 2.129. Hose No.2 of the crankcase ventilation system
Disconnect PCV hose #2 from the PCV valve (fig. 2.129).
Remove the 3 engine wiring harness mounting clamps from the bracket.
Fig. 2.130. Fastening the cylinder head cover
Remove 9 bolts, 2 sealing washers, 2 nuts, 3 mounting brackets, then remove the cylinder head cover (fig. 2.130).
Removal the poly V-belt tensioner assembly
Fig. 2.131. Fastening the poly V-belt tensioner
Remove the bolt and nut, then remove the poly V-belt tensioner (fig. 2.131).
Note: To remove the bolt, rock the tensioner up and down.
Removal the right engine mount bracket
Fig. 2.132. Right engine support bracket mounting bolts
Remove 3 bolts, then remove the right engine mount bracket (fig. 2.132).
Remove the coolant pump assembly.
Fig. 2.133. Crankshaft position sensor mounting bolts
Remove 2 bolts and disconnect the crankshaft position sensor (fig. 2.133).
Setting the piston of cylinder No.1 to TDC of the compression stroke
Turn the crankshaft pulley and align the mark on it with the synchronizing mark "0" on the timing chain drive cover.
Fig. 2.134. Setting the piston of cylinder No.1 to TDC of the compression stroke
Make sure that the marks (dots) on the camshaft drive gears are located opposite each other, as shown in Figure 2.134.
Otherwise, rotate the crankshaft 1 revolution (360°) and align the marks as shown above.
Removal the crankshaft pulley
Fig. 2.135. Removing the crankshaft pulley
With SST 09960-10010 (09962-01000, 09963-01000) remove the crankshaft pulley mounting bolt (fig. 2.135).
Remove the pulley from the crankshaft.
Removal chain tensioner #1
Fig. 2.136. Removing tensioner No.1
Remove 2 nuts, then remove the chain tensioner (fig. 2.136).
Note: Do not rotate the crankshaft unless the chain is tensioned by the tensioner.
Removal the timing chain or belt drive cover
Remove 10 bolts and 2 nuts.
Using a TORX E8 socket wrench, unscrew the stud.
Fig. 2.137. Timing belt cover mounting bolts
Separate the timing cover by inserting a screwdriver between the cover, cylinder head and cylinder block (fig. 2.137).
Note: Be careful not to damage the mating surfaces of the timing cover, cylinder block and cylinder head.
Removal the timing chain or belt drive cover seal
Place the timing belt cover on wooden blocks.
Fig. 2.138. Removing the seal
Use a screwdriver to remove the seal (fig. 2.138).
Removal the toothed disk of the crankshaft position sensor No.1
Fig. 2.139. Toothed disk of the crankshaft angular position sensor
Remove the crankshaft position sensor toothed disk from the crankshaft (fig. 2.139).
Removal the chain tensioner shoe
Fig. 2.140. Chain tensioner shoe mounting bolt
Remove the bolt and chain tensioner shoe (fig. 2.140).
Removal the chain assembly
Fig. 2.141. Removing the chain
Using 2 screwdrivers, remove the chain together with the drive gear, as shown in Figure 2.141.
Note: Place a rag under the screwdriver to avoid damaging the engine.
If it is necessary to turn the camshafts with the chain removed from the gears, the crankshaft should be turned 1/4 turn to avoid contact between the valves and the pistons.
Installing the chain assembly
Set the piston of cylinder No.1 to TDC of the compression stroke.
Fig. 2.142. Alignment of marks on drive gears
Turn the camshafts by the hexagonal part so that the 2 marks (dots) on the drive gears are located opposite each other (fig. 2.142).
Fig. 2.143. Alignment of the key of the drive gear with the dot mark on the oil pump
Turn the crankshaft by the crankshaft pulley mounting bolt so that the key of the timing gear is aligned with the dot mark on the oil pump (fig. 2.143).
Fig. 2.144. Alignment of the link with the yellow mark with the synchronizing mark on the gear
Install the chain onto the timing gear, aligning the link with the yellow mark with the timing mark on the gear (fig. 2.144).
Fig. 2.145. Installing the timing gear on the crankshaft
Using SST 09223-22010, install the timing gear to the crankshaft (fig. 2.145).
Fig. 2.146. Alignment of links with yellow mark with synchronizing marks on camshaft gears
Install the chain onto the camshaft drive gears, aligning the links with the yellow mark with the synchronizing marks on the camshaft gears (fig. 2.146).
Install the chain tensioner shoe and secure it with the bolt.
Tightening torque: 18.5 Nm.
Fig. 2.147. Mark "F" on the toothed disk of the crankshaft angular position sensor
Install the crankshaft position sensor toothed disk with the "F" mark toward the front of the vehicle (fig. 2.147).
Installing the timing chain or belt drive cover seal
Lubricate the seating surface of the new seal with a thin layer of general-purpose grease.
Place the timing belt cover on wooden blocks.
Fig. 2.148. Pressing in a new seal
Using SST 09223-22010, press in a new seal until its surface is flush with the edge of the timing cover (fig. 2.148).
Note: The seal seating surface must be free of sand, dirt and other foreign particles.
Installing the timing chain or belt drive cover
Remove any remaining old sealant from the mating surface.
Fig. 2.149. Places of sealant application
Apply the sealant in a continuous bead (diameter 3.5–4.5 mm) as shown in Figure 2.149.
Note: Clean mating surfaces from oil.
Install the oil pan within 3 minutes after applying the sealant.
Add oil to the engine no earlier than 2 hours after installing the pan.
Fig. 2.150. Sealant placement diagram from the timing belt cover side
Be especially careful when applying sealant to area D – do not exceed the specified amount (fig. 2.150).
Fig. 2.151. Timing belt cover fastening bolts and nuts
Secure the timing chain cover with 10 bolts and 2 nuts (fig. 2.151).
Tightening torque: 13 Nm for bolt A and nut A, 18.5 Nm for bolt B.
Using a TORX E8 socket wrench, tighten the stud.
Tightening torque: 9.5 Nm.
Installing the chain tensioner assembly No.1
Fig. 2.152. Plunger mounting hook
Make sure there is no dirt on the sealing ring, then install the hook as shown in Figure 2.152.
Apply a thin layer of engine oil to the sealing ring.
Secure the chain tensioner with 2 nuts.
Tightening torque: 9.0 Nm.
Note: Be careful not to crush the sealing ring.
If the hook comes loose and releases the plunger while installing the chain tensioner, re-secure the plunger with the hook.
Installing the crankshaft pulley
Align the key on the shaft with the groove in the pulley, then slide the pulley onto the crankshaft.
With SST 09960-10010 (09962-01000, 09963-01000) tighten the crankshaft pulley mounting bolts.
Tightening torque: 138 Nm.
Fig. 2.153. Position of the crankshaft when removing the plunger
Turn the crankshaft counterclockwise, then remove the hook from the locking pin and release the plunger (fig. 2.153).
Fig. 2.154. Checking the plunger operation
Turn the crankshaft clockwise and make sure the plunger presses on the chain tensioner shoe (fig. 2.154).
If the plunger does not extend, use a screwdriver to press the shoe towards the tensioner until the hook disengages from the locking pin and the plunger can extend.
Installing the crankshaft position sensor
Apply a thin layer of engine oil to the crankshaft position sensor O-ring.
Secure the crankshaft position sensor with 2 bolts.
Tightening torque: 9.0 Nm.
Install the coolant pump assembly.
Install the right engine mount bracket.
Tightening torque: 47 Nm.
Install the poly V-belt tensioner assembly.
Installing the cylinder head cover
Remove any remaining old sealant from the mating surface.
Fig. 2.155. Places of sealant application
Apply sealant in 2 points as shown in Figure 2.155.
Note: Clean mating surfaces from oil.
Note: Install the cylinder head cover within 3 minutes after applying the sealant.
Note: Do not add oil to the engine earlier than 2 hours after installing the cylinder head cover.
Fig. 2.156. Cylinder head cover fastening bolts and nuts
Secure the cylinder head cover and 3 mounting brackets with 9 bolts, 2 sealing washers and 2 nuts (fig. 2.156).
Tightening torque: 11 Nm for bolt A and nut A, 9.0 Nm for bolt B.
Install 3 engine wiring harness clamps onto the brackets.
Connect hose No.2 of the crankcase ventilation system.
Connect the crankcase ventilation hose.
The installation of the remaining components is carried out in the reverse order of removal.