Двигатель zd30 руководство по ремонту

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Серёга Шумахер » 10 янв 2017, 11:22

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SECTION

ENGINE MECHANICAL

CONTENTS

●Before starting work, make sure no fire or spark producing items are in the work area.

●Release fuel pressure before disassembly.

●After disconnecting pipes, plug openings to stop fuel leakage.

●When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.

● Exercise maximum care to avoid damage to mating or sliding surfaces.

● Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. ● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

● When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified.

●Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

●Use torque wrench to tighten bolts or nuts.

●When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.

● Replace with new gasket, packing, oil seal or O-ring.

● Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage.

● Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.

●Release air within route after draining coolant.

●After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems

for leakage.

●Use an angle wrench for the final tightening of the following engine parts:

– Cylinder head bolts

– Connecting rod cap nuts

●Do not use a torque value for final tightening.

●The torque value for these parts are for a preliminary step.

●Ensure thread and seat surfaces are clean and coated with engine oil.

PRECAUTIONS

[KA24DE]

REMOVAL OF LIQUID GASKET SEALING

●After removing the mounting bolts and nuts, disconnect and remove the liquid gasket sealing using a seal cutter.

CAUTION:

Be careful not to damage the mating surfaces.

●In areas where the cutter is difficult to use, use a plastic hammer to lightly tap the areas where the liquid gasket is applied.

CAUTION:

If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating sur-

faces.

PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE

1.Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface.

●Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts, and bolt holes.

2.Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.

3.Attach the liquid gasket to the tube presser.

Use Genuine Liquid Gasket or equivalent.

PBIC0003E

4.Apply the gasket without breaks to the specified location with the specified dimensions.

●If there is a groove for the liquid gasket application, apply the gasket to the groove.

●As for the bolt holes, normally apply the gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of service manual.

●Within five minutes of gasket application, install the mating component.

●Do not retighten after the installation.

●After 30 minutes or more have passed from the installation, fill the engine oil and coolant.

CAUTION:

If there are specific instructions in the service manual, observe them.

ZZA0022D

KV10105001

Engine attachment

ZZA0046D

KV10114700

Main bearing cap remover

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

PBIC0192E

ENGINE ROOM COVER

KBIA0741E

REMOVAL

1.Open engine compartment LH cover and secure it.

2.Remove RH seat. Refer to SE-4, «FRONT SEAT» .

3.Partially remove floor carpet.

4.Disconnect harness protector secured together at front right. Disconnect harness connector to move harness routed on top of engine compartment RH cover aside.

5.Move parking brake lever and cable from engine compartment RH cover. Refer to PB-3, «PARKING BRAKE SYSTEM» .

6.Remove mounting bolts, and remove engine compartment RH cover.

CAUTION:

When taking it out of vehicle, do not allow it to interfere with vehicle.

INSTALLTION

●Install in reverse order of removal following instructions below.

1.Temporarily tighten bolt No. 1 shown in the figure.

2.Tighten bolt No. 2 shown in figure to specified torque.

3.Tighten other bolts except bolt “A” shown in the figure (bolt No. 1 is included) to specified torque in any given order.

4.Close engine compartment LH cover.

5.Tighten bolt “A” shown in the figure to specified torque.

REMOVAL

1.Move folded seat on engine compartment rear cover side rearward, if applicable.

2.Partially remove floor carpet.

3.Remove mounting bolts, and remove engine compartment rear cover.

ENGINE ROOM COVER

1.Tighten bolts No. 1 to No. 3 shown in the figure to specified torque in this order.

C

D

E

F

G

KBIA0742E

H

I

J

K

L

M

WARNING:

Be sure to perform when the engine is stopped.

●Inspection should be done only when engine is cold, or over 30 minutes after engine is stopped.

●Measure belt tension with tension meter (special service tool) at points marked shown in the figure.

●Measure belt deflection by applying load of 98.1 N {10 kg} to .

PBIC0422E

CAUTION:

●When belt is replaced with a new one, tighten it a little stronger than current one to accommodate for insufficient adaptability with pulley grooves.

●When tension of belt being used exceeds ″Retightening limit″, adjust it to value for ″Used belt″.

●When installing belt, make sure that it is correctly engaged with pulley groove.

●Keep oil and water away from belt.

●Do not twist or bend belt excessively.

POWER STEERING PUMP BELT

1.Open and fix engine compartment LH cover.

2.Loosen idler pulley lock nut (A) and adjust tension by turning adjusting bolt (B).

●For specified belt tension, refer to EM-14, «Checking Drive Belts» .

3.Tighten nut (A).

: 25.5 — 32.4 N·m (2.6 — 3.3 kg-m, 19 — 23 ft-lb)

EMK0571D

AIR CONDITIONER COMPRESSOR BELT

1.Open and fix engine compartment LH cover (passenger side for RHD models or driver-side for LHD models).

2.Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D). ● For specified belt tension, refer to EM-14, «Checking Drive Belts» .

3.Tighten nut (C).

: 25.5 — 32.4 N·m (2.6 — 3.3 kg-m, 19 — 23 ft-lb)

ALTERNATOR AND WATER PUMP BELT

1.Remove front-side under cover.

2.Remove RH seat. Refer to SE-4, «FRONT SEAT» .

3.Remove engine compartment RH cover. Refer to EM-12, «ENGINE ROOM COVER» .

4.Loosen alternator mounting bolt (E) and adjuster lock bolt (F), and adjust tension by turning adjusting nut

(G).

● For specified belt tension, refer to EM-14, «Checking Drive Belts» .

5.Tighten bolts (E), (F) and (G).

REMOVAL

●Loosen each belt while referring to «Adjustment», and remove them one by one starting from the one in front.

INSTALLATION

1.Install belts to pulley in reverse order of removal.

2.Adjust belt tension.

CAUTION:

●When checking belt tension immediately after installation, first, adjust to specified value. Then, after turning crankshaft more than two turns, re-adjust to specified value to avoid variation in deflection between pulleys.

●Tighten idler pulley lock nut by hand and measure tension without looseness.

3.Tighten each adjusting bolt and nut to the specified torque.

4.Make sure that tension of each belt is within the standard.

AIR CLEANER AND AIR DUCT

KBIA0821E

REMOVAL

1.Remove rear-side under cover.

2.Open and fix engine room LH cover.

3.Remove RH seat. Refer to SE-4, «FRONT SEAT» .

4.Remove engine room RH cover. Refer to EM-12, «ENGINE ROOM COVER» .

5.Remove floor cover behind RH seat.

6.Disconnect harness connector from airflow sensor.

AIR CLEANER AND AIR DUCT

[KA24DE]

REMOVAL

NOTE:

●Mark ″*″ in the figure shows part of lift arm.

●For replacement of air cleaner element, it is not necessary to lift up vehicle.

1.Remove brake pipe protector under vehicle, behind front RH wheel.

2.Remove 3 clips, and the cover at the bottom of air cleaner case.

3.Remove wing nut, dust pan under air cleaner case, and then air cleaner element.

KBIA0749E

INSTALLATION

Install in the reverse order of removal.

REMOVAL

1.Remove RH seat. Refer to SE-4, «FRONT SEAT» .

2.Remove engine compartment RH cover. Refer to EM-12, «ENGINE ROOM COVER» .

3.Remove air duct on throttle body. Refer to EM-16, «AIR CLEANER AND AIR DUCT» .

4.Disconnect accelerator cable, and set it aside.

5.Disconnect harness connector.

6.Disconnect water hose.

● After disconnection, plug the hose to prevent coolant leaks.

7.Loosen mounting bolts in reverse order shown in the figure, and remove throttle body.

THROTTLE BODY

[KA24DE]

INSPECTION AFTER REMOVAL

●If idle is rough when engine is cold or warmed up, check and adjust the fast idle cam (FIC). Refer to EC28, «Fast Idle Cam (FIC) Inspection and Adjustment» .

INSTALLATION

Install in reverse order of removal, paying attention to points below.

●For throttle body, tighten mounting bolts in two steps in the numerical order shown in the figure.

●For adjustment of accelerator cable, refer to ACC-3, «ACCELERATOR CONTROL SYSTEM (KA24DE)» .

1st step : 8.8 — 10.8 N·m (0.9 — 1.1 kg-m, 78 — 95 in-lb)

2nd step : 17.7 — 21.6 N·m (1.8 — 2.2 kg-m, 13 — 15 ft-lb)

PBIC0425E

DISASSEMBLY

Disassemble referring to the component illustration.

ASSEMBLY

Assemble in reverse order of disassembly, paying attention to points below.

●Insert throttle position sensor into throttle body, with connectors positioned as shown in the figure. Then rotate it in the direction shown by arrow and temporarily tighten mounting screws.

●While they are turned in direction shown by arrow, circumference of sensor hits projection. Avoid hitting projection by giving slight space, and insert projection into inside of mounting screw long hole. (It is temporarily held in place by counter-action of spring.)

●After adjustment on vehicle, tighten mounting screws.

For adjusting procedure, refer to EC-45, «Basic Inspection» .

PBIC0426E

PBIC0427E

M

REMOVAL

1.Release fuel pressure. Refer to EC-27, «Fuel Pressure Release» .

2.Drain coolant. Refer to CO-9, «ENGINE COOLANT» .

3.Remove RH seat. Refer to SE-4, «FRONT SEAT» .

4.Remove engine compartment RH cover and rear cover. Refer to EM-12, «ENGINE ROOM COVER» .

5.Remove floor cover behind RH seat.

INTAKE MANIFOLD

[KA24DE]

6.Move aside main harness above intake manifold.

7.Disconnect PCV hose between rocker cover and air duct.

8.Remove air duct between throttle body and mass air flow sensor. Refer to EM-16, «AIR CLEANER AND AIR DUCT» .

9.Remove throttle body. Refer to EM-19, «THROTTLE BODY» .

10.Remove fuel tube and injector assembly. Refer to EM-28, «FUEL INJECTOR AND FUEL TUBE» .

11.Disconnect radiator hose (upper).

12.Disconnect hoses connected to intake manifold.

NOTE:

Separate water hose and PCV hose behind intake manifold when removing intake manifold.

13.Remove intake manifold with the following procedure.

a.Loosen mounting bolts and nuts in reverse order shown in the figure.

b.Pull out stud bolts on rear.

c.Disconnect water hose and PCV hose on back side, and remove intake manifold.

PBIC0428E

INSPECTION AFTER REMOVAL

Surface Distortion

●Using straightedge and feeler gauge, inspect surface distortion of intake manifold.

PBIC0429E

INSTALLATION

Assemble in reverse order of removal, paying attention to the following.

Intake Manifold Bolts

●Tighten in numerical order as shown in the figure.

: 15.7 — 18.6 N·m (1.6 — 1.8 kg-m, 12 — 13 ftlb)

PBIC0428E

Water Outlet

●Install gasket so that identification mark face as shown in component parts drawing.

REMOVAL

KBIA0826E

EXHAUST MANIFOLD

[KA24DE]

6.Loosen mounting nuts in reverse order shown in the figure, and remove exhaust manifold.

PBIC0430E

INSPECTION AFTER REMOVAL

●Using straightedge and feeler gauge, inspect surface distortion of intake manifold.

PBIC0431E

INSTALLATION

Install in the reverse order of removal, paying attention to the following.

●Tighten in numerical order as shown in the figure.

: 37.3 — 48.1 N·m (3.8 — 4.9 kg-m, 28 — 35 ft-lb)

PBIC0430E

INSPECTION AFTER INSTALLATION

Start engine, and check for exhaust gas leakage and unusual noise by increasing engine speed.

OIL PAN AND OIL STRAINER

REMOVAL

WARNING:

To avoid the danger of being scalded, never drain the engine oil when the engine is hot.

1.Remove under covers on front-side, and rear-side.

2.Drain engine oil. Refer to LU-5, «ENGINE OIL» .

3.Loosen mounting bolts in reverse order shown in the figure, and remove them.

NOTE:

There are no screw holes in the area marked with on cylinder block. (No mounting bolts.)

4.Using a seal cutter (special service tool), separate liquid gasket, and remove oil pan.

5.Remove oil strainer.

SEM980F

INSPECTION AFTER REMOVAL

Check oil strainer and clean it if any object attached.

INSTALLATION

Install in the reverse order of removal paying attention to the following.

OIL PAN AND OIL STRAINER

[KA24DE]

Installing Oil Pan

1.Apply liquid gasket thoroughly as shown in illustration. ● Use Genuine Liquid Gasket or equivalent.

PBIC0433E

2.Tighten mounting bolts in numerical order as shown in the figure.

NOTE:

There are no screw holes in the area marked with on cylinder block. (No mounting bolts.)

SEM985F

Installing Drain Plug Washer

Refer to illustration of component parts for installation direction.

INSPECTION AFTER INSTALLATION

Check for leakage of engine oil when engine is warmed.

SPARK PLUG (CONVENTIONAL)

●Remove and install No. 4 cylinder by connecting extension bar of 75 mm and universal socket to spark plug wrench.

D

E

SMA581C

INSPECTION AFTER REMOVAL

Check spark plug gap. Adjust or replace if necessary.

●Use a wire brush for cleaning, if necessary.

INSTALLATION

Install in the reverse order of removal, paying attention to the following.

Spark plug:

: 20 — 29 N·m ( 2.0 — 3.0 Kg-m, 14 — 22 ft-lb)

●Refer to EM-30, «ROCKER COVER» for installation of spark plug cap and high-tension cables.

L

M

FUEL INJECTOR AND FUEL TUBE

KBIA0827E

CAUTION:

●Apply new engine oil when installing the parts that specified to do so in the figure.

REMOVAL

1.Release fuel pressure. Refer to EC-27, «Fuel Pressure Release» .

2.Remove RH seat. Refer to SE-4, «FRONT SEAT» .

3.Remove engine compartment RH cover. Refer to EM-12, «ENGINE ROOM COVER» .

4.Disconnect PCV hose between rocker cover and air duct.

5.Remove air duct on throttle body. Refer to EM-16, «AIR CLEANER AND AIR DUCT» .

6.Disconnect fuel injector harness connector.

7.Move aside main harness above intake manifold.

8.Disconnect vacuum hose from fuel tube.

9.Disconnect fuel feed hose and fuel return hose.

CAUTION:

Plug hoses to prevent fuel from draining.

10.Remove fuel tube and injector assembly.

CAUTION:

Do not incline it, or remaining fuel in pipes may drain from pipes.

FUEL INJECTOR AND FUEL TUBE

[KA24DE]

11.Expand and remove clips securing fuel injectors.

12.Extract fuel injectors straight from fuel tubes.

●Be careful not to damage injector nozzles during removal.

●Do not bump or drop fuel injectors.

●Do not disassemble.

PBIC0227E

INSTALLATION

2.Position clips in grooves on fuel injectors.

●Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.

3.Align protrusions of fuel tubes with those of fuel injectors.

4.Do not incline it, or remaining fuel in pipes may drain from pipes.

●Insert hose until its end touches bulge on fuel tube. Install clamp, avoiding bulge, and securely tighten it.

5.Tighten fuel tube assembly mounting bolts alternatively in two steps.

PBIC0227E

1st step : 7.8 — 10.8 N·m (0.8 — 1.1 kg-m, 69 — 95 ft-lb)

2nd step :15.7 — 18.6 N·m (1.6 — 1.8 kg-m, 12 — 13 ft-lb)

6.Connect fuel feed nose and fuel return hose.

●Insert hose until its end touches bulge on fuel tube. Install clamp, avoiding bulge, and securely tighten it.

7.Install all removed parts in the reverse order of removal.

INSPECTION AFTER INSTALLATION

Check on Fuel Leakage

1.Start the engine, and run it for a few minutes with engine at idle.

2.Stop the engine, and check for fuel leakage both visually and by odor of gasoline.

NOTE:

Use mirrors for checking on invisible points.

CAUTION:

Do not touch the engine immediately after stopped, as engine becomes extremely hot.

KBIA0828E

REMOVAL

1.Open and fix engine compartment LH cover.

2.Remove engine compartment rear cover. Refer to EM-12, «ENGINE ROOM COVER» .

3.Disconnect PCV hose.

4.Disconnect spark plug cap and high-tension cables, and set them aside.

5.Loosen mounting bolts in reverse order shown in the figure, and remove rocker cover.

PBIC0434E

INSTALLATION

Install in the reverse order of removal, paying attention to the following.

CAUTION:

Apply new engine oil to parts marked in illustration before installation.

REMOVAL

1.Remove following parts.

●Power steering pump belt (Refer to EM-14, «DRIVE BELTS» .)

●Power steering pump support bracket

●Idler pulley bracket for power steering pump belt

●Rocker cover (Refer to EM-30, «ROCKER COVER» .)

2.Set No.1 cylinder to TDC in compression stroke.

a.Rotate crankshaft pulley clockwise and align notch of matching marks (yellow paint) to timing indicator on front cover.

PBIC0437E

CAMSHAFT

[KA24DE]

5.Remove camshaft sprockets.

●Hold secondary timing chain in place, using chain stopper (special service tool) to prevent it from slipping from idler sprocket.

PBIC0441E

6.Loosen mounting bolts of camshaft brackets in several steps in the numerical order shown in the figure, and remove them.

7.Remove camshaft.

8.Remove adjusting shim and valve lifter.

●Check mounting positions, and store them without mixing them up.

PBIC0442E

INSTALLATION

1.Install valve lifters and adjusting shims.

●Install them in their original positions.

●Install adjusting shims with their stamp marks facing downward (valve lifter side).

2.Install camshaft.

●Intake and exhaust are identified by direction of No. 1 cylinder cam nose when knock pin at front end faces straight upward.

For intake:

Cam nose faces toward intake manifold side For exhaust:

Cam nose faces toward exhaust manifold side

PBIC0443E

●Install camshafts so that knock pins at front end face straight upward (position of No.1 cylinder at compression TDC).

PBIC0444E

CAMSHAFT

4.Tighten camshaft bracket mounting bolts in two steps in numerical order shown in the figure.

CAUTION:

Tighten them from outside toward inside.

1st step : 2.0 N·m (0.2 kg-m, 18 in-lb)

2nd step :9.0 — 11.8 N·m (0.92 — 1.2 kg-m, 80 — 104 ft-lb)

PBIC0442E

●Hold hexagonal part of camshaft with spanner, and tighten camshaft sprocket mounting bolt.

NOTE:

Each camshaft has one hexagonal part at both front and rear, respectively.

6.Pull out stopper pins from secondary timing chain tensioner.

7.Check and adjust valve clearance. Refer to EM-38, «Valve Clearance» .

8.Install other parts in reverse order of removal.

INSPECTION AFTER REMOVAL

Camshaft Runout

●Put V block on, and support No.1 and No.5 journal of camshaft.

●Set dial gauge vertically to No.3 journal.

●Turn camshaft to one direction with hands, and measure camshaft runout (Total indicator reading) on dial gauge.

SEM926C

CAMSHAFT

[KA24DE]

Camshaft Cam Height

1.Measure camshaft cam height.

Standard:

Intake: 41.755 — 41.945 mm (1.644 — 1.651 in)

Exhaust: 41.815 — 42.005 mm (1.646 — 1.654 in)

Limit:

Intake and exhaust: 0.2 mm (0.008 in)

2.If wear is beyond the limit, replace camshaft.

PBIC0039E

Camshaft Journal Clearance

Outer Diameter of Camshaft Journal

●Measure outer diameter of camshaft journal.

Inner Diameter of Camshaft Bracket

●Tighten camshaft bracket bolt with specified torque.

●Using inside micrometer, measure inner diameter of camshaft bracket.

Calculation of Camshaft Journal Clearance

(Journal clearance) = (inner diameter of camshaft bracket) – (outer diameter of camshaft journal)

●When out of the specified range above, replace either or both camshaft and cylinder head.

NOTICE:

Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder head assembly.

Camshaft End Play

●Install dial gauge in thrust direction on front end of camshaft. Measure end play of dial gauge when camshaft is moved forward/backward (in direction to axis).

●When out of the specified range, replace with new camshaft and measure again.

●When out of the specified range again, replace with new cylinder head.

PBIC0446E

CAMSHAFT

8.Determine replacement adjusting shim size as follows.

a.Using a micrometer determine thickness of removed shim.

b.Calculate thickness of new adjusting shim so valve clearance comes within specified values.

R = Thickness of removed shim N = Thickness of new shim

M = Measured valve clearance (Hot)

Shims are available in thicknesses from 1.96 mm (0.0772 in) to

2.68 mm (0.1055 in), in steps of 0.02 mm (0.0008 in).

c.Select new shim with thickness as close as possible to calculated value.

Refer to EM-88, «VALVE» .

9.Install new shim using a suitable tool.

●Install with the surface on which the thickness is stamped facing down.

10.Place Tool (A) as mentioned in steps 2 and 3.

11.Remove Tool (B).

12.Remove Tool (A).

13.Recheck valve clearance.

Refer to EM-38, «INSPECTION» .

Valve clearance:

*: Approximately 20°C (68°F)

SECONDARY TIMING CHAIN

CAUTION:

Apply new engine oil to parts marked in illustration before installation.

NOTE:

●This section describes removal and installation procedure of secondary timing chain along with removal and installation of cylinder head.

●Procedure for removal and installation of camshaft is described in EM-32, «CAMSHAFT» , as it is different from description in this section.

REMOVAL

1.Release fuel pressure. Refer to EC-27, «Fuel Pressure Release» .

2.Drain engine coolant from radiator and cylinder block. Refer to CO-9, «ENGINE COOLANT» .

SECONDARY TIMING CHAIN

[KA24DE]

3.Remove driver seat. Refer to SE-4, «FRONT SEAT» .

4.Remove engine compartment RH cover and rear cover. Refer to EM-12, «ENGINE ROOM COVER» .

5.Remove floor cover behind RH seat.

6.Adjust No. 1 cylinder to TDC position in compression stroke. Refer to EM-32, «CAMSHAFT» .

7.Remove following parts.

●Intake manifold: Refer to EM-21, «INTAKE MANIFOLD» .

●Exhaust manifold: Refer to EM-23, «EXHAUST MANIFOLD» .

●Drive belts: Refer to EM-14, «DRIVE BELTS» .

●Radiator shroud (Upper and lower)

●Cooling fan: Refer to CO-20, «COOLING FAN» .

8.Remove power steering oil pump. Fix it along with reservoir tank on vehicle with rope or similar means.

CAUTION:

Fix reservoir tank to prevent power steering fluid from leaking.

9.Remove power steering pump bracket, and idler pulley bracket for power steering pump belt.

10.Remove rocker cover. Refer to EM-30, «ROCKER COVER» .

11.Remove camshaft sprocket, and camshaft. Refer to EM-32, «CAMSHAFT» .

NOTE:

The following steps in removal procedure are not necessary at this point.

●Step 2: Application of matching marks to secondary timing chain

●Step 5: Fixing of secondary timing chain

12.Remove cylinder head front cover with the following procedure.

a.Remove all mounting bolts (A — G) of cylinder head front cover.

PBIC0449E

b.Completely loosen cylinder head bolts in reverse order shown in the figure.

●Do not remove cylinder head at this point. (Remove it in step 16.)

SEM274D

c.Slightly tap cylinder head front cover from back side with an appropriate wooden bar to remove it.

EMK0486D

PBIC0440E

SECONDARY TIMING CHAIN

[KA24DE]

3.Fix primary timing chain by inserting chain stopper (special service tool) to prevent it from slipping from crankshaft sprocket.

EMK0490D

–Chain stopper is difficult to pull out because of interference with idler sprocket large-diameter side when being removed. Use it after circumference of upper surface is chamfered.

4.Remove idler sprocket, and idler shaft.

CAUTION:

Do not carry idler shaft with idler sprocket large-diameter side facing downward to prevent it from falling off.

PBIC0453E

16. Remove cylinder head and cylinder head gasket.

INSPECTION AFTER REMOVAL

Timing Chain

Check timing chain for cracks and excessive wear at roller links.

Replace chain if necessary.

SEM984C

Idler Sprocket End Play

●Install idler sprocket to cylinder head, and tighten mounting bolts to specified torque.

●Set dial gauge to idler sprocket front end.

●Move idler sprocket in thrust direction (back-and-forth), and read indication on gauge.

Standard : 0.2 — 0.3 mm (0.008 — 0012 in)

EMK0538D

SECONDARY TIMING CHAIN

[KA24DE]

Idler Sprocket Oil Clearance

Idler Sprocket Inner Diameter

●Using inside micrometer measure the inner diameter.

EMK0539D

Idler Shaft Outer Diameter

●Using micrometer measure the outer diameter.

EMK0129D

Calculation of Idler Sprocket Oil Clearance

●(Idler sprocket oil clearance) = (Idler sprocket inner diameter) – (Idler shaft outer diameter)

●If outside the standard, replace either idler sprocket, idler shaft, or both, referring to standard value of