TIMING CHAIN
EM-51
< ON-VEHICLE REPAIR >[HR16DE]
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4. Remove the following parts.
Intake manifold: Refer to EM-29, "
Exploded View".
Drive belt: Refer to EM-16, "
Removal and Installation".
Water pump pulley: Refer to CO-20, "
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 EM-89, "
Exploded View".
6. Remove rocker cover. Refer to EM-47, "
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. Make sure the matching marks on each camshaft sprocket are
positioned as shown.
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 mounting bolts as they are used as a sup-
porting point for the pulley puller.
c. Attach a pulley puller [SST: KV11103000] (A) in the M 6 thread
hole on crankshaft pulley, and remove crankshaft pulley.
B : White paint mark (Not use for service)
PBIC3673E
1 : Camshaft sprocket (EXH)
2 : Camshaft sprocket (INT)
A : Matching mark (stamp)
B : Matching mark (peripheral stamp line)
PBIC3872E
PBIC3710E
B: M6 bolt
PBIC3711E
TIMING CHAIN
EM-57
< ON-VEHICLE REPAIR >[HR16DE]
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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.
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 is in the reverse order of removal, for the remaining parts.
InspectionINFOID:0000000001381413
INSPECTION AFTER REMOVAL
Timing Chain
KBIA3429J
: 35.0 N·m (3.6 kg-m, 26 ft-lb)
PBIC3726E
EM-60
< ON-VEHICLE REPAIR >[HR16DE]
CAMSHAFT
5. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-89, "
Exploded View".
6. Remove rocker cover. Refer to EM-47, "
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. Make sure the matching marks on each camshaft sprocket are
positioned as shown.
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 mounting bolts as they are used as a sup-
porting point for the pulley puller.
c. Attach a pulley puller [SST: KV11103000] (A) in the M 6 thread
hole on crankshaft pulley, and remove crankshaft pulley.
9. Remove front cover with the following procedure:
B : White paint mark (Not use for service)
PBIC3673E
1 : Camshaft sprocket (EXH)
2 : Camshaft sprocket (INT)
A : Matching mark (stamp)
B : Matching mark (peripheral stamp line)
PBIC3872E
PBIC3710E
B: M6 bolt
PBIC3711E
EM-62
< ON-VEHICLE REPAIR >[HR16DE]
CAMSHAFT
The sprocket (C) and vane (camshaft coupling) (B) are
designed to spin and move within the range of a certain
angle.
With the engine stopped and the vane in the most
retarded angle, it will not spin because it is locked to the
sprocket side by the internal lock pin (A).
If the camshaft sprocket mounting bolts are turned in the
situation described above, the lock pin will become dam-
aged and cause malfunctions because of the increased
horizontal load (cutting force) on the lock pin.
a. Remove camshaft bracket (No. 1) (1).
Loosen the bolts in several steps, and then remove them.
b. Apply the following air pressure to the No. 1 journal oil hole (A)
of camshaft (INT) (1) shown using an air gun.
Apply the air pressure into the oil hole on the second groove
from the front of camshaft thrust (B).
Proceed all the way through step “e” with the air pressure on.
Attach the rubber nozzle (B) narrowed to the top of the air gun
(A) to prevent air leakage from the oil hole. Securely apply the
air pressure to the oil hole.
CAUTION:
There are other oil holes in the side grooves. Never use
the incorrect oil holes.
Be sure not to damage the oil path with the tip of the air
gun.
Wipe all the oil off the air gun to prevent oil from being
blown all over along with the air, and the area around the
air gun should be wiped with a rag when applying air
pressure. Eye protection should be worn as needed.
NOTE:
The air pressure is used to move the lock pin into the disengage position.
c. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alter-
natively.
Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the
arrow ( )].
Perform the work while applying the air pressure to the oil hole.
PBIC3679E
: Engine front
AWBIA0103ZZ
Pressure
: 300 kPa (3.0 bar, 3.1 kg/cm2 , 44 psi) or more
AWBIA0104ZZ
AWBIA0105ZZ
CAMSHAFT
EM-63
< ON-VEHICLE REPAIR >[HR16DE]
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If the lock pin is not released by hands, tap the camshaft
sprocket (INT) lightly with a plastic hammer (A).
If the camshaft sprocket (INT) is not rotated counterclockwise
even if the above procedures are performed, check the air
pressure and the oil hole position.
d. While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the camshaft sprocket
(INT), start turning the camshaft sprocket (INT) in the counter-
clockwise direction in the most advanced angle position.
Keep the air pressure on.
If there is no click, as soon as the vane-side (camshaft side)
starts moving independently of the sprocket, the lock pin has
become disengaged.
Make sure that it is in the most advanced angle position by
seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown.
e. Complete the applying procedure of air pressure and the holding procedure of camshaft (INT).
f. Insert the stopper pin (A) into the stopper pin holes in the cam-
shaft sprocket (INT) and lock in the most advanced angle posi-
tion.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.).
Since it comes out easily, secure it with tape (B) to prevent
it from coming out.
NOTE:
The stopper pin shows one example of a hexagonal wrench for
2.5 mm (0.098 in) [length of inserted section: approximately15
mm (0.59 in)].
13. Remove camshaft brackets (No. 2 to 5).
Loosen bolts in several steps in the reverse of the order
shown.
NOTE:
The camshaft bracket (No. 1) has been already removed.
14. Remove camshaft (EXH).
AWBIA0106ZZ
C : Most retarded angle (lock pin engaged)
D : Most advanced angle
PBIC3684E
AWBIA0107ZZ
A : EXH side
B : INT side
: Engine front
PBIC3686E
CAMSHAFT
EM-69
< ON-VEHICLE REPAIR >[HR16DE]
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18. Pull out the stopper pin (A), and then apply the tension to the
timing chain by rotating the crankshaft pulley clockwise slightly.
19. Return the camshaft sprocket (INT) in the most retarded position with the following procedure.
a. Remove the stopper pin (A) from the camshaft sprocket (INT).
b. Turn the crankshaft slowly clockwise and return the camshaft sprocket (INT) to the most retarded angle
position.
When first turning the crankshaft the camshaft sprocket (INT)
will turn. Once it is turned more, and the vane (camshaft) also
turns, then it has reached the most retarded angle position.
The most retarded angle position can be checked by seeing if
the stopper pin groove (A) is shifted clockwise.
After spinning the crankshaft slightly in the counterclockwise
direction, you can make sure the lock pin has joined by seeing
if the vane (camshaft) and the sprocket move together.
20. Install the front oil seal to the front cover. Refer to EM-78, "
FRONT OIL SEAL : Removal and Installation"
21. Install front cover with the following procedure:
1 : Plunger
2 : Chain tensioner
B: Lever
C: Lever hole
D : Front cover has been omitted
PBIC3772E
B: Tape
AWBIA0107ZZ
B : Stopper pin hole
C : Most advanced angle
D : Most retarded angle (lock pin engaged)
PBIC3705E
CAMSHAFT
EM-71
< ON-VEHICLE REPAIR >[HR16DE]
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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.
22. 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.
23. 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.
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.
24. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
25. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
Tighten bolts with it seated completely.
26. Check and adjust valve clearance. Refer to EM-21, "
Inspection and Adjustment".
27. Installation is in the reverse order of removal, for the remaining parts.
InspectionINFOID:0000000001381416
INSPECTION AFTER REMOVAL
Oil Filter
KBIA3429J
: 35.0 N·m (3.6 kg-m, 26 ft-lb)
PBIC3726E
EM-82
< ON-VEHICLE REPAIR >[HR16DE]
CYLINDER HEAD
In this step, loosen bolts in reverse order of that indicated.
d. Tighten all bolts.
e. Turn all bolts 75 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100] (A) or protractor. Avoid judg-
ment by visual inspection without the tool.
f. Turn all bolts 75 degrees clockwise again (angle tightening).
3. Installation is in the reverse order of removal, for the remaining parts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
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-19, "
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 leak-
age 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.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing 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.
Summary of the inspection items:
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Disassembly and AssemblyINFOID:0000000001381422
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
PBIC3733E
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —