Removal

• Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection. • Turn the crankshaft pulley so that the No.1 piston is at top dead center.

1.	Disconnect the battery negative cable (A).

2.	Remove the air duct (A).

3.	Remove the engine cover (A).

4.	Remove the intake air hose and air cleaner assembly. (1) Disconnect the AFS connector (A). (2) Disconnect the breather hose (B) from air cleaner hose. (3) Remove the intake air hose(C) and air cleaner body (D).

5.	Remove the RH front wheel.

6.	Remove the under cover(A).

7.	Remove the side cover.

8.	Loosen the drain plug and drain the engine coolant.

9.	Drain the engine oil.

10.	Disconnect the ground cable (A) and loosen the power steering hose mounting bolt (B).

11.

Remove the surge tank and engine wiring. (1) Disconnect the RH front and rear oxygen sensor connectors(A), the power steering sensor connector(B), the RH injector harness connector(C) and the VIS solenoid valve connector(D). (2) Disconnect the RH ignition coil connector. (3) Disconnect the OCV connector (A) and the knock sensor connector (B). (4) Disconnect the LH front oxygen sensor connector (C). (5) Disconnect the alternator connector (D) and the air compressor connector (E). (6) Disconnect the LH ignition coil connector (A), the injector connector (B), the condenser connector (C) and the ground (D), and remove the wiring harness protector (E). (7) Disconnect the RH CMPS (A) and the OTS connector (B). (8) Disconnect the PCSV connector (A), the MAP sensor connector (B) and the PCSV hose. (9) Disconnect the ETC connector (A) and the knock sensor connector (B). (10) Disconnect the water hoses (B) from ETC and PCV(C) hose. (11) Disconnect the TCU connector(A) and CKP sensor connector(B). (12) Disconnect the LH rear oxygen sensor connector(A). (13) Disconnect brake vacuum hose. (14) Remove the breather pipe assembly (A). (15) Remove the surge tank stays (A). (16) Remove the connector bracket (A) from the surge tank. (17) Remove the surge tank (A). Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.

12.	Remove the cylinder head cover. (1) Remove the connector bracket (A) from LH cylinder head cover. (2) Disconnect the RH ignition coil connector (A), condenser connector (B) and remove the wiring bracket (C). (3) Remove the LH, RH ignition coil. (4) Remove the LH, RH cylinder head cover (A).

13.	Using SST (09215-3C000) remove lower oil pan (A). Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.

14.	Set a jack to the upper oil pan.

15.	Remove the PCM & relay box cover and loosen the relay box mounting bolts.

16.	Remove the engine mounting bracket (A).

17.

Set No.1 cylinder to TDC/compression. (1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover. Do not rotate engine counterclockwise. (2) Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°). Do not rotate engine counterclockwise.

18.	Remove the drive belt (A).

19.

Remove the crankshaft damper pulley (A). There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. • Install the SST (09231-3C300) to hold the ring gear after removing the starter. • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover. 1. Remove the front muffler. (Refer to Intake And Exhaust system) 2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B). 3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth. 4. Fasten the two transaxle mounting bolts in the original mounted holes. 5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.

20.	Lift up the engine assembly to using the jack.

21.	Remove the drive belt idler (A).

22.	Remove the drive belt auto tensioner (A).

23.	Remove the water pump pulley (A).

24.

Remove the timing chain cover (A). If necessary remove the water pump (B) first. Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.

25.	Install a set pin after compressing the timing chain tensioner.

26.	Remove the RH cam-to-cam guide (A).

27.	Remove the RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).

28.	Remove the RH timing chain.

29.	Remove the RH timing chain guide (A).

30.	Remove the oil pump chain cover (A).

31.	Remove the oil pump chain tensioner assembly (A).

32.	Remove the oil pump chain guide (A).

33.	Remove the oil pump chain sprocket (A) and oil pump chain (B).

34.	Remove the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

35.	Install a set pin after compressing the LH timing chain tensioner.

36.	Remove the LH cam-to-cam guide (A).

37.	Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

38.	Remove the LH timing chain.

39.	Remove the LH timing chain guide (A).

40.	Remove the crankshaft sprocket (A) (LH camshaft drive).

41.	Remove the tensioner adapter assembly (A).

Inspection

Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm

1.	Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.

2.	Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.

3.	Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

Installation

1.	Install the jack to the upper oil pan.

2.	The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.

3.	Install the tensioner adapter assembly (A).

4.	Install the crankshaft sprocket (A) (LH camshaft drive).

5.	Install the LH timing chain guide (A). Tightening torque 19.60 ~ 24.50Nm(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

6.

Install LH timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below. Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket(C) → Intake camshaft sprocket(D). The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.

7.	Install the LH timing chain tensioner arm(B). Tightening torque 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

8.	Install the LH chain tensioner (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

9.	Install the LH cam-to-cam guide (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

10.	Install the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

11.	Install the oil pump chain (B) and oil pump sprocket (A). Tightening torque 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

12.	Install the RH timing chain guide (A). Tightening torque 19.60 ~ 24.50Nm(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

13.

Install the RH timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below. Crankshaft sprocket (A) → Intake camshaft sprocket (B) → Exhaust camshaft sprocket (C). The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.

14.	Install the RH timing chain tensioner arm (B). Tightening torque 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

15.	Install the RH timing chain auto tensioner (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

16.	Install the RH cam-to-cam guide (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

17.	Install the oil pump chain guide (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

18.	Install the oil pump chain tensioner assembly (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

19.	Pull out the pins of hydraulic tensioners (LH & RH).

20.	Install the oil pump chain cover (A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

21.	After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark. Always turn the crankshaft clockwise.

22.

Install the timing chain cover. (1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC. (2) Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied. Bead width : 2.5mm(0.1in.) (3) After applying liquid sealant TB1217H on the timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied without discontinuity. Bead width : 2.5mm(0.1in.) (4) Install the new gasket (A) to the timing chain cover. During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts. (5) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position. Tightening torque B(17) :18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft) C(4) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) D(1) :58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft) E(1) :58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft) F(2) :24.50 ~ 26.46N.m (2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft) G(4) :21.56 ~ 23.52N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft) H(1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) I(1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) J(1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) K(4) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) L(1):21.56 ~ 26.46N.m (2.2 ~ 2.7kgf.m, 15.91 ~ 19.53lb-ft) - New bolt (6) The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.

23.	Install the water pump pulley (A). Tightening torque 7.84 ~ 9.80Nm(0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

24.	Install the drive belt auto tensioner (A). Tightening torque Bolt(B) : 81.39 ~ 85.32N.m (8.3 ~ 8.7kgf.m, 60.03 ~ 62.93lb-ft) Bolt(C) : 17.64 ~ 21.56N.m (1.8 ~ 2.2kgf.m, 13.02 ~ 15.91lb-ft)

25.	Install the drive belt idler (A). Tightening torque 52.92 ~ 57.82Nm(5.4 ~ 5.9kgf.m, 39.06 ~ 42.67lb-ft)

26.	Lower the engine assembly by using the jack.

27.	Using SST (09231-3C100), install timing chain cover oil seal.

28.

Install the crankshaft damper pulley (A). Tightening torque 284.2~303.8N.m (29.0~31.0kgf.m, 209.76~224.22lb-ft) There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. • Install the SST (09231-3C300) to hold the ring gear after removing the starter. • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover. 1. Remove the front muffler. (Refer to Intake And Exhaust system) 2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B). 3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth. 4. Fasten the two transaxle mounting bolts in the original mounted holes. 5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.

29.

Install the drive belt (A). Crankshaft pulley → A/C pulley → idler pulley → alternator pulley → water pump pulley → P/S pump pulley→ tensioner pulley. Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

30.

Install the cylinder head cover. (1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover. (2) After applying sealant (TB1217H), it should be assembled within 5 minutes. Bead width : 2.5mm(0.1in.) (3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled. (4) Install the cylinder head cover bolts as following method. Tightening torque 9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) Do not reuse cylinder head cover gasket. (5) Install the ignition coil. (6) Connect the RH ignition coil connector (A), the condenser connector (B) and install the wiring bracket (C). (7) Install the connector bracket (A) from LH cylinder head cover.

31.

Install the surge tank and wiring connectors. (1) Install the surge tank (A). Tightening torque 9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (2) Install the connector bracket (A) to the surge tank. Tightening torque 6.86 ~ 10.78N.m (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft) (3) Install the surge tank stays (A). Tightening torque 27.44 ~ 31.36N.m (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft) (4) Install the breather pipe assembly (A). Tightening torque 9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (5) Connect the brake vacuum hose. (6) Connect the LH rear oxygen sensor connector(A). (7) Connect the TCU connector(A) and CKP sensor connector(B). (8) Connect the water hoses (B) to the ETC and PCV(C) hose. (9) Connect the ETC connector (A) and knock sensor connector (B). (10) Connect the PCSV connector (A), the MAP sensor connector (B) and the PCSV hose. (11) Disconnect the RH CMPS (A) and the OTS connector (B). (12) Install the wiring harness protector (E) and connect the LH ignition coil connector (A), the injector connector (B), the condenser connector (C) and the ground (D). (13) Connect the alternator connector (D) and the air compressor connector (E). (14) Connect the LH front oxygen sensor connector (C). (15) Connect the OCV connector (A) and the knock sensor connector (B). (16) Connect the RH ignition coil connector. (17) Disconnect the RH front and rear oxygen sensor connectors (A), the power steering sensor connector (B), the RH injector harness connector (C) and the VIS solenoid valve connector (D).

32.	Connect the ground cable (A) and tighten the power steering hose mounting bolt (B).

33.	Install the engine mounting bracket (A). Tightening torque B: 78.5 ~ 98.0N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft) C: 63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

34.	Tighten the relay box mounting bolts and install the PCM & relay box cover.

35.	Remove the jack from the upper oil pan.

36.

Install the lower oil pan. (1) Using a gasket scraper, remove all the old packing material from the gasket surfaces. (2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied. Bead width : 2.5mm(0.1in.). But marked area(*) to be 5.0mm(0.2in.) 1) Make clean the sealing face before assembling two parts. 2) Remove harmful foreign matters on the sealing face before applying sealant. 3) When applying sealant gasket, sealant must not be protruded into the inside of oil pan. 4) To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. (3) Install the lower oil pan (A). Tightening torque 9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

37.	Install the side cover. Tightening torque 8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)

38.	Install the under cover (A). Tightening torque 8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)

39.	Install the RH front wheel. Tightening torque 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

40.	Install the intake air hose and air cleaner assembly. (1) Install the intake air hose(C) and air cleaner body (D). (2) Connect the breather hose (B) to the air cleaner hose. (3) Connect the AFS connector (A).

41.	Install the engine cover (A).

42.	Install the air duct (A).

43.

Connect the battery negative cable (A). • Refill engine with engine oil. • Refill radiator and reservoir tank with engine coolant. • Bleed air from the cooling system. - Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.) - Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. - Put radiator cap on tightly, then run the engine again and check for leaks.