Engine mechanism - Timing chain assembly

(b) Coat engine oil on the chain tensioner, and then install

it.

Torque:  

Note:  when installing the chain temsioner, buckle

on the hook again if plunger has ejected.

33.

Install damping pulley.

(a) Align the key groove on the damping pulley with the

key on the crankshaft, and slide damping pulley in.

(b) Install damping pulley bolts with special tool.

             Torque:  

(c) Turn crankshaft counterclockwise to separate the hook

from lock pin on the plunger.

(d) Turn crankshaft clockwise, and check the chain ten-

sion rail is blocked by plunger.

Hint: if the plunger does not eject, press the chain ten-

sion rail toward chain tensioner with screwdriver

or fingers to separate the hook from lock pin and

make the plunger eject.

Special

tool

 49 

Pushing into

Separation

Hook

Pin

Turning

Plunger

Pushing

into

Turning

Engine mechanism - Timing chain assembly

34.

Install speed sensor.

Torque:  

35.

Install engine fixing bracket

Torque: 

36.

Install water pump mounting components

     [4G18-1307100].

(a) Install new o-ring on water pump.

(b) Install water pump with 6 bolts.

Torque:  bolt A:  

m

37.

Install drive belt tensioner device.

Torque:  nut:  

                       Bolt:  

m

38.

Install right engine mounting assembly.

Torque:  

39.

Install cylinder head cover components.

(a) Install gasket to cylinder head cover.

(b) Eliminate all old seal materials.

(c) Coat sealant on 2 positions shown in the diagram.

Sealant:  silicon rubber flange sealant 1596

(Kesaixin 1596).

Notes:

Eliminate all grease on contact surface.

After coating sealant, finish installation of cylinder

head cover within 3 minutes.

After installing, do not refill engine oil within 2

minutes.

(d) Install cylinder head cover and cable bracket with 9 bolts,

2 seal washers and 2 nuts.

Torque:  nut:  

                            Bolt: 

m

40.

Install ignition coil mounting components.

Torque:  

50 

Engine mechanism - Timing chain assembly

41.

Install alternator mounting components.

Torque: 12mm bolt head: 

                      14mm bolt head:  

m

42.

Refill coolant.

43.

Check there is coolant leakage.

44.

Check there is oil leakage.

 51 

Engine mechanism - Camshaft

Camshaft

Replacement

1. Remove engine hood.

2. Remove ignition coil assembly.

3. Remove cylinder head cover assembly.

4. Remove engine right bottom shield.

5. Turn crankshaft to cylinder 1 compression top dead

center position.

(a) Turn damping pulley to align its groove with “o” mark on

timing chain hood.

(b) Check dot marks on camshaft timing sprocket and VVT

timing sprocket, and they should be in a line on timing chain

hood surface as shown in the diagram.

Hint: if not, turn crankshaft for one circle (360

) again

and align the above marks.

6. Remove drive belt.

Slowly turn drive belt tensioner clockwise to loosen it.Then

remove drive belt and put back drive belt tensioner slowly and

gently.

7. Remove right engine mounting assembly.

(a) Remove PS oil pump reservoir and put it aside.

(b) Place wooden block between jack and engine, properly

place the jack, and then remove engine fixing bracket shock

absorber.

8. Remove drive belt  tensioner assembly.

Hint:  operate the jack up and down to remove bolts.

 52

Mark

Mark

Mark

Timing  chain

hood surface

Groove