EM-52
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TIMING CHAIN
1. Remove front wheel and tire (RH). Refer to
WT-48, "Removal and Installation".
2. Remove front fender protector (RH). Refer to EXT-38, "
Removal and Installation".
3. Drain engine oil. Refer to LU-8, "
Draining".
CAUTION:
• Perform this step when engine is cold.
• Do not spill engine oil on drive belt.
4. Drain coolant. Refer to CO-8, "
Draining Engine Coolant".
5. Remove the drive belt. Refer to EM-16, "
Removal and Installation".
6. Remove the rocker cover. Refer to EM-48, "
Removal and Installation".
7. Remove the water pump pulley. Refer to CO-18, "
Removal and Installation".
8. Support the bottom surface of engine (1) using a transmission jack (2), and then remove engine mounting insulator (RH). Refer
to EM-86, "
Exploded View".
CAUTION:
• Position a suitable jack under the engine and transaxle assembly as shown.
• Do not damage the front exhaust tube or transaxle oil pan with the jack.
9. Set No. 1 cylinder at TDC of its compression stroke:
a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
b. Check the matching marks on each camshaft sprocket are posi- tioned as shown.
• If not, rotate crankshaft pulley one more turn to align matchingmarks to the positions.
10. Remove crankshaft pulley:
ALBIA0894GB
(B) : White paint mark (Not use for service)
PBIC3673E
(1) : Timing chain
(2) : Camshaft sprocket (EXH)
(3) : Camshaft sprocket (INT)
(A) : Matching mark (Peripheral groove)
(B) : Pink link
(C) : Matching mark (Peripheral groove)
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EM-56
< REMOVAL AND INSTALLATION >[HR16DE]
TIMING CHAIN
a. Install the crankshaft sprocket (1), the oil pump drive chain (2),
and the oil pump sprocket (3) at the same time.
• Install the crankshaft sprocket so that its invalid gear area (A)is toward the back of the engine.
• Install the oil pump sprocket so that its protrusion faces 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 socket (size: E8), and then tighten the oil pump sprocket nut.
c. Install oil pump drive chain tensioner (1). • Insert the body into the shaft (B) while inserting the spring intothe attaching 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:
• Install by aligning matching marks on each sprocket and tim-ing chain.
• If these matching marks are not aligned, rotate the camshaft
slightly to correct the position.
CAUTION:
• After the matching marks are aligned, keep them aligned by holding them.
• To avoid skipped teeth, do not rotate crankshaft and cam- shaft until front cover is installed.
: Engine front
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(1) : Crankshaft sprocket
(2) : Oil pump drive chain
(3) : Oil pump sprocket
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(A) : Matching mark (Peripheral groove)
(B) : Pink link
(C) : Matching mark (Peripheral groove)
(D) : Orange link
(E) : Matching mark (stamp)
(F) : Crankshaft key (point straight up)
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TIMING CHAINEM-57
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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 EM-74, "
FRONT OIL SEAL : Removal and Installation".
7. Install front cover with the following procedure:
a. Apply a continuous bead of liquid gasket to the engine block joint locations (A) as shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22, "
Recommended Chemical Products
and Sealants"
CAUTION:
• Do not confirm torque after the 5 minutes have elapsed.
• Then allow 30 minutes for the liquid gasket to set before
adding oil to the engine.
b. Apply a continuous bead of liquid gasket to front cover as shown using suitable tool. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22, "
Recommended Chemical Products
and Sealants".
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PBIC3722E
(1) : Cylinder head
(2) : Cylinder block
(3) : Oil pan (upper)
(A) : Liquid gasket application area [3.0 - 4.0 mm (0.12 - 0.16 in) diam-
eter]
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TIMING CHAINEM-59
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• 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. Check that crankshaft turns smoothly by rotating by hand clockwise using suitable tool.
11. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels, includi ng engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-11, "
Fluids and Lubricants".
• Use procedure below to check for fuel leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks at connection points.
• Start engine. With engine speed increased, check again for fuel leaks at connection points.
• Run engine to check for unusual noise and vibration. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there are no lea ks of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
*Power steering fluid, brake fluid, etc.
Crankshaft pulley bolt : 35.0 N·m (3.6 kg-m, 26 ft-lb)
PBIC3726E
ItemBefore starting engine Engine runningAfter engine stopped
Engine coolant LevelLeaks Level
Engine oil LevelLeaks Level
Transmission/
transaxle fluid CVT Models
LeaksLevel/Leaks Leaks
M/T Models Level/Leaks LeaksLevel/Leaks
Other oils and fluids* LevelLeaks Level
Fuel LeaksLeaks Leaks
Exhaust gas —Leaks —
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EM-68
< REMOVAL AND INSTALLATION >[HR16DE]
CAMSHAFT
• 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-11, "
Fluids and Lubricants".
• Use procedure below to check for fuel leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks
at connection points.
• Start engine. With engine speed increased, che ck again for fuel leaks at connection points.
• Run engine to check for unusual noise and vibration. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leak s of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
*Power steering fluid, brake fluid, etc.
InspectionINFOID:0000000012431722
INSPECTION AFTER REMOVAL
Oil Filter
• Check that there is no foreign material on the oil filter (1) and check it for clogging.
• Check the oil filter for damage.
• If there is some damage, replace the oil filter, the plug, and the washer as a set.
CAUTION:
Do not reuse the washer.
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour- nals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft
sprocket) because it has a differe nt diameter from the other
four locations.
2. Set a suitable tool vertically to No. 3 journal.
3. Turn camshaft to one direction, and measure the camshaft runout using suitable tool. (Total indicator reading)
Item Before starting engine Engine runningAfter engine stopped
Engine coolant LevelLeaks Level
Engine oil LevelLeaks Level
Transmission/
transaxle fluid CVT Models
LeaksLevel/Leaks Leaks
M/T Models Level/Leaks LeaksLevel/Leaks
Other oils and fluids* LevelLeaks Level
Fuel LeaksLeaksLeaks
Exhaust gas —Leaks —
PBIC3693E
PBIC2499E
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CAMSHAFTEM-71
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• Measure the outer diameter of valve lifter using suitable tool (A).
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head using suit-
able tool (A).
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
• If out of the standard, referring to the each standard of
valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 or P 0014 is detected in self-diagnostic results of CON-
SULT and it is directed according to insp ection procedure of EC section. Refer to EC-168, "
Diagnosis
Procedure" (P0011) or EC-172, "Diagnosis Procedure" (P0014).
• Check when engine is cold so as to pr event burns from the splashing engine oil.
NOTE:
This section provides the inspection method of oil passage of cam sprocket on the intake side. For oil passage
on the exhaust side, the inspection proc edure must be changed as instructed below:
1. Check engine oil level. Refer to LU-7, "
Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a. Release the fuel pressure. Refer to EC-137, "
Work Procedure".
b. Remove intake manifold. Refer to EM-28, "
Removal and Installation".
Standard : Refer to
EM-117, "
Camshaft".
PBIC3185J
Standard : Refer to EM-117, "Camshaft".
PBIC3184J
Standard : Refer to EM-117, "Camshaft".
· Step 3 : Remove exhaust valve timing control solenoid valve. Refer to EM-60, "Exploded View".
· Step 4 : Crank engine, and then check that engine oil comes out from exhaust valve timing control solenoid
valve hole (A). End crank after checking.
·Step 5 Perform the following inspection if engine oil does not come out from exhaust valve timing control
solenoid valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to
EM-60, "
Exploded View".
• Clean oil groove between oil strainer and exhaust valve timing control solenoid valve. Refer to
EM-60, "
Exploded View".
·Step 6 : Remove components between exhaust valve timing control solenoid valve and camshaft sprocket
(EXH), and then check each oil groove for clogging.
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EM-72
< REMOVAL AND INSTALLATION >[HR16DE]
CAMSHAFT
c. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to
EM-60, "
Exploded View".
4. Crank engine, and then check that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank
after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
• Prevent splashing by using a shop cloth to prevent injuryfrom splashing engine oil and so as to prevent engine oil contamination.
• Use a shop cloth to prevent engine oil from bein g splashed to engine and vehicle. Especially be
careful not to spill engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe
engine oil off immediatel y if it is splashed.
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to LU-10, "
Removal and Installation".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-5,
"Engine Lubrication System".
6. Remove components between intake valve timing c ontrol solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-5, "
Engine Lubrication System".
7. After inspection, installation of components is in the reverse order of removal
(1) : Plug
:Engine front
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CYLINDER HEADEM-77
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1. Install new cylinder head gasket.
CAUTION:
Do not reuse cylinder head gasket.
2. Install cylinder head, and tighten cylinder head bolts in order as shown using Tool (A). • Clean threads and seating surfaces of bolts.
• Apply new engine oil to threads and seating surface of bolts.
CAUTION:
• If cylinder head bolts are reu sed, check their outer diameters before installation. Refer to EM-80,
"Inspection".
• Check and confirm the tighteni ng angle by using Tool (A).
Do not judge by visual insp ection without the Tool (A).
3. Installation of the remaining components is in the reverse order of removal. Tool number (A) : KV10112100 (BT-8653-A)
AWBIA1426ZZ
Step 1 : 40.0 N·m (4.1 kg-m, 30 ft-lb)
Step 2 : 60
° clockwise in order
Step 3 : 0 N·m (0 kg-m, 0 ft-lb)
Step 4 : 40.0 N·m (4.1 kg-m, 30 ft-lb)
Step 5 : 75 ° clockwise in order
Step 6 : 75 ° clockwise in order
: Engine frontAWBIA1425ZZ
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