1. Chain guide at the bend; 2. Timing chain tensioner; 3. Exhaust camshaft sprocket; 4. Timing chain; 5. Oil filler cap; 6. Front cover; 7. O-ring; 8. Electrovalve of the intake valve timing control mechanism; 9. Crankshaft pulley bolt; 10. Crankshaft pulley; 11. Front oil seal; 12. Automatic drive belt tensioner; 13. Timing chain tensioner guide (from the side in front of it the cover); 14. Crankshaft sprocket; 15. Balancing block sprocket; 16. Purpose of the balancing block drive; 17. Intake camshaft sprocket; 18. Timing chain tensioner guide; 19. O-ring; 20. Balancing block drive chain tensioner; A. See below; Q. See below.
Removal and installation
Removal
Attention. The direction of rotation indicated in the text refers to rotation as viewed from the front of the engine.
1. Remove the front right wheel.
2. Remove the protective trim from the right front fender. See chapter "Interior and exterior equipment".
3. Drain the engine oil. See chapter "Engine lubrication and cooling system".
Attention. Perform this operation when the engine is cold
4. Remove the following components.
- intake manifold; see above;
- valve cover; see above;
- drive belt; see above.
5. Set the piston of cylinder No. 1 to TDC on the compression stroke as follows:
A. Turn the crankshaft pulley (1) clockwise and align the TDC mark (colorless risk) (8) with timing indicator (A) on the front cover.
C. White paint mark (not used during maintenance).
b. At the same time, make sure that the working lobes of the camshafts of the intake and exhaust camshafts of the cylinder are facing each other () as shown in the picture.
1. Intake camshaft.
2. Exhaust camshaft.
- Otherwise, turn the crankshaft pulley one more turn (360°) and arrange them as shown in the picture.
6. Remove the crankshaft pulley as follows:
A. Lock the crankshaft pulley (1) holder (A) (suitable special tools), loosen the crankshaft pulley bolt so that it moves 10 mm from its original position.
Attention. Do not unscrew the crankshaft pulley bolt, because it will serve as a point of contention for the pulley puller (special tool: KV111030000).
b. Attach the crankshaft pulley puller (A) (special tool: KV111030000) in the M6 holes of the crankshaft pulley and remove the crankshaft pulley.
7. Remove the rear reaction rod. See below.
8. Support the bottom of the engine with a telescopic stand and remove the stand and insulator of the right engine mount. See below.
9. Oil pan (lower). See above.
Note. If the crankshaft sprocket and balancing block components are not removed, this step can be skipped.
10. Remove the intake valve timing control solenoid valve.
11. Remove the automatic drive belt tensioner.
12. Remove the front cover as follows:
A. Loosen the mounting bolts in the reverse order shown in the illustration.
b. Pry up the cover in the places indicated by the arrows () in the picture, cut off the sealant and remove the front cover.
Attention:
- Do not damage the contact surfaces.
- When shipped from the factory, a more durable sealant is applied than previously used sealants. Therefore, you should not try to separate the cover in places not intended for this purpose.
13. Remove the front oil seal from the front cover.
Attention:
- Be careful not to damage the front cover.
- Remove the front oil seal using a screwdriver.
14. Remove the chain tensioner as follows.
A. Press in the chain tensioner plunger.
b. Insert the locking pin (A) into the hole in the tensioner body and fix it with the plunger pressed in.
Note. A metal rod with a diameter of approx. 1.5 mm.
With. Remove the chain tensioner. (1)
15. Remove the timing chain guide at the bend (2) timing chain tensioner guide (3) and timing chain (1).
Attention. After removing the timing chain, do not rotate the crankshaft or camshaft separately, otherwise the valve will collide with the piston crowns.
16. Remove the sprocket from the crankshaft and the balance block components as follows:
A. Raise the lever fully (A) and press the timing chain guide at the bend (IN) to the drive chain tensioner (oil pump) (1).
- The guide at the bend is released when the lever is fully raised. As a result, it can be moved.
b. Insert the locking pin (D) into the hole in the tensioner housing (WITH) and fix the timing chain guide at the bend.
Note. A metal rod with a diameter of approx. 1-2 mm.
With. Remove the balancing block drive chain tensioner.
- If the hole in the arm does not line up with the hole in the tensioner housing, align them by slightly moving the guide where it bends.
d. Secure the balance shaft at the hexagonal part (19.0 mm) (A) and loosen the balance block sprocket bolt.
1. Oil pan (upper).
Attention:
- Fix the balancing block shaft by the hexagonal part.
- Do not loosen the balance block sprocket bolt while tensioning the balance block drive target.
e. Remove the crankshaft sprocket, the balancing block sprocket and the balancing block drive chain included.
17. If necessary, remove the timing chain tensioner guide (from the front cover) from the front cover.
Installation
Note. The illustration shows the relative position of the alignment marks on the chains and on the corresponding sprockets after installing the components.
1. Make sure the crankshaft key is facing straight up.
1. Timing chain; 2. Camshaft sprocket (release); 3. Chain guide at the bend; 4. Timing chain tensioner; 5. Balancing block sprocket; 6. Drive chain of the balancing block; 7. Tensioner for the balancing block drive target; 8. Crankshaft sprocket; 9. Timing chain tensioner guide; 10. Camshaft sprocket (inlet); A. Registration mark (dark blue link); B. Registration mark (knocked out); C. Crankshaft key (facing straight up); D. Alignment mark (knocked out); E. Registration mark (orange link); F. Alignment mark (external groove).
- There are two grooves on the periphery of the intake camshaft sprocket. The wider one is the registration mark.
2. If the timing chain tensioner guide was removed (from the front cover) install it into the front cover.
Attention. Verify that the components engage by sound or feel.
3. Install the crankshaft sprocket (2) balancing block sprocket (3) and drive chain of the balancing block (1).
A. Registration mark (knocked out).
B. Registration mark (orange link).
C. Registration mark (dark blue link).
- Perform installation by aligning the marks on all sprockets and on the balancing block drive chain.
- If the marks do not align, rotate the balance shaft slightly and align.
Attention. Make sure that the alignment marks on the sprockets have not moved after installing the balancing block drive chain.
4. Fix the balance shaft at the hexagonal part (19.0 mm) (A) and tighten the balance block sprocket bolt.
1. Oil pan (upper).
Attention:
- Fix the balancing block shaft by the hexagonal part.
- Do not loosen the balancing block sprocket bolt while tensioning the balancing block drive chain.
5. Install the balancing block drive chain tensioner (1).
- Push in the plunger and hold it pressed in with the locking pin (A) install the tensioner.
- After installing the balancing block drive chain tensioner, carefully remove () locking pin.
- Make sure that the alignment marks on the balancing block drive chain and on the sprockets have not moved.
6. Align the marks on each sprocket and timing chain.
1. Camshaft sprocket (release); 2. Camshaft sprocket (inlet); 3. Timing chain; A. Registration mark (dark blue link); B. Registration mark (knocked out); C. Registration mark (external groove*); D. Alignment mark (orange link); E. Registration mark (knocked out).
*There are two grooves on the periphery of the intake camshaft sprocket. The wider one is the registration mark.
- If the marks do not align, rotate the camshaft slightly by grasping the hexagonal part and aligning it.
Attention. Make sure that the alignment marks on the sprockets have not moved after installing the timing chain.
7. Install the timing chain tensioner guide (3) and chain guide at the bend point (2).
1. Timing chain.
8. Install the timing chain tensioner (1).
- Push in the plunger and hold it pressed in with the locking pin (A) install the tensioner.
- After installing the timing chain tensioner, carefully remove the locking pin.
9. Check again that the alignment marks on the sprockets and timing chain have not moved.
10. Press in the front oil seal. See below.
11. Install the front cover as follows:
A. Insert the new O-ring into the cylinder block.
Attention. Do not allow the O-ring to become dislodged.
b. Apply sealant (IN) continuous strip using a syringe (suitable special tools) onto the front cover as shown in the figure.
- Use branded sealant or equivalent.
With. Make sure the marks on the timing chain and sprockets are still aligned. Then install the front cover.
Attention:
- Make sure the O-ring is inserted into the cylinder block correctly.
- Do not damage the front oil seal on the front end of the crankshaft.
A. Area for applying sealant.
d. Install the front cover and tighten the mounting bolts in the order indicated by the numbers in the figure.
The bolt locations are shown below.
- M6: No. 1.
- M10: No.6, 7, 10, 11, 14.
- M12: No. 2, 4, 8, 12.
- M8: Except as stated above.
Attention. Installation should be performed within 5 minutes after applying the sealant.
e. After tightening the bolts, tighten them with the required torque in the order indicated by the numbers in the figure.
Attention. Remove any excess sealant that has come out on the surface.
12. Install the crankshaft pulley as follows:
A. When pressing the crankshaft pulley with a plastic hammer, strike the central area (not around the circumference).
Attention. Be careful not to damage the lip of the front oil seal.
b. Lock the crankshaft pulley (1) pulley holder (A) (suitable special tools).
With. Apply fresh engine oil to the threads and seating surface of the crankshaft pulley bolt.
d. Tighten the crankshaft pulley bolt.
: 68.6 Nm (7.0 kg-m).
e. Loosen completely.
: 0 Nm (0 kg-m).
f. Tighten the crankshaft pulley bolt.
: 29.4 Nm (3.0 kg-m).
g. Mark with paint (IN) to the crankshaft pulley (2) opposite any of the six corner marks (A) on flange (1) crankshaft pulley bolt.
h. Tighten the bolt 60°clockwise (angle tightening).
- Check the tightening angle using the corner marks.
i. Turn the crankshaft pulley clockwise by hand and make sure it rotates freely.
13. Install the remaining components in the reverse order of removal.
Check after removal
Timing chain
Check for cracks (A) or excessive wear (IN) on the plates and roller links of the timing chain. If necessary, replace the timing chain.
Check after installation
Leak check
- Below are procedures to check for fluid, engine oil, and exhaust leaks.
- Before starting the engine, check the oil/fluid levels including engine coolant and engine oil. If the level is below normal, add and bring to the required level. See chapter "Maintenance".
- Check for fuel leaks as follows:
Turn the ignition key to the ON position (without starting the engine). After creating pressure in the fuel lines, check for fuel leaks at the joints.
Start the engine. While increasing the engine speed, check again for fuel leaks at the joints of the fuel lines.
- Run the engine and check for unusual noise or vibration.
Note. If the hydraulic pressure inside the timing chain tensioner drops after removal/installation as a result of slack in the guide, a dull knock may occur when the engine starts and immediately after. However, this does not indicate a malfunction. The knocking noise will stop when the hydraulic pressure rises.
- Warm up the engine thoroughly and check for fuel or oil/fluid leaks, including engine oil and engine coolant.
- Bleed the air from the pipes and hoses of the relevant systems, such as the cooling system.
- After the engine has cooled, check the oil/fluid levels again including engine oil and engine coolant. If necessary, top up and bring to the required level.
Check table
Component | Before starting the engine | Engine running | After stopping the engine |
Engine coolant | Level | Leakage | Level |
Motor oil | Level | Leakage | Level |
Other oils and liquids* | Level | Leakage | Level |
Fuel | Leakage | Leakage | Leakage |
*Fluid for manual transmission, automatic transmission, CVT power steering, brake fluid, etc.