NOTE:
Variable valve timing actuator can not be disassembled because it is a precision unit
.
Intake camshaft sprocket is integrated with the variable valve timing actuator and cannot be disassembled.
1. Remove the battery cover..
2. Disconnect the negative battery cable.
3. Remove the plug hole plate..
4. Disconnect the wiring harness.
5. Remove the ignition coils..
6. Remove the spark plugs..
7. Remove the ventilation hose.
8. Remove the oil level gauge.
9. Remove the cylinder head cover..
10. Remove the aerodynamic under cover No.2 and splash shield as a single unit..
11. Remove the generator drive belt with the A/C drive belt still installed and set it out of the way. (MZR 2.0).
12. Remove the drive belt. (MZR 2.5).
13. Remove the engine front cover lower blind plug.
14. Remove the engine front cover upper blind plug.
15. Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (MTX).
16. Remove the cylinder block lower blind plug, and install the SST.
17. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at top dead center (TDC) of the compression stroke. (Until the counterweight contacts SST
and stops.)
18. Loosen the timing chain using the following procedure.
a. Insert a suitable bolt (M6 X 1.0, length 25—35 mm {1.0—1.3 in})
into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)
b. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.
c. Using a Hex bit socket (2.5 mm {0.098 in})
or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.
d. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.
NOTE:
The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.
e. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.
NOTE:
The racket has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.
If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.
19. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.
20. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer (The washers may not be installed.) as a single unit.
CAUTION:
Perform the work carefully so that the washer does not drop out. (The washers may not be installed.)
NOTE:
The washers do not have to be installed on the MZR 2.0 (ATX) (there is no problem with installing them).
Be careful not to install a washer on only the IN or EX side.
21. Remove the OCV..
22. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.
NOTE:
The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.
23. Remove the variable valve timing actuator and the camshaft on the intake air side as a single unit.
24. Remove the variable valve timing actuator.
a. Mark the camshaft and variable valve timing actuator as shown in the figure to make sure they are installed in their original position.
b. Secure the camshaft in a vise.
c. Loosen the variable valve timing actuator tightening bolt.
25. Install a new washer. (Except MZR 2.0 (ATX).)
NOTE:
The washers do not have to be installed on the MZR 2.0 (ATX) (there is no problem with installing them).
Be careful not to install a washer on only the IN or EX side.
If the washers are not installed, do not install the washers to both the IN and EX sides.
If the washers are to be installed, install them on both the IN and EX sides.
26. Install the variable valve timing actuator.
NOTE:
When the variable valve timing actuator is replaced with a new one, mark it in the same location as the old one.
a. Secure the camshaft in a vise.
b. Align the marks of the camshaft and variable valve timing actuator.
c. Tighten variable valve timing actuator tightening bolt.
69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}
NOTE:
If the alignment marks on the variable valve timing actuator are not available, refer to the “TIMING CHAIN ASSEMBLY” in the engine workshop manual and perform the sprocket position alignment again.
27. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST
.)
28. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.
29. With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timing actuator and the camshaft on the intake air side as a single unit.
30. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.
31. Temporarily tighten the camshaft cap bolts evenly in 2—3 steps.
32. Tighten the camshaft cap bolts in the order shown in the following two steps.
Step 1: 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}
Step 2: 14—17 N·m {1.5—1.7 kgf·m, 11—12 ft·lbf}
33. Install the OCV..
34. Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer (Except MZR 2.0 (ATX).) as a single unit.
CAUTION:
Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer. (Except MZR 2.0 (ATX).)
Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.
NOTE:
The washers do not have to be installed on the MZR 2.0 (ATX) (there is no problem with installing them).
Be careful not to install a washer on only the IN or EX side.
If the washers are not installed, do not install the washers to both the IN and EX sides.
If the washers are to be installed, install them on both the IN and EX sides.
35. Install the SST
on the camshaft as shown in the figure.
36. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25—35mm {1.0—1.3 in})
, and apply tension to the timing chain.
37. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.
69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}
38. Remove the SST
from the camshaft.
39. Remove the SST
installed in the cylinder block lower blind plug hole.
40. Rotate the crankshaft clockwise two turns and inspect the valve timing.
If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 34.
41. Install the cylinder block lower blind plug.
18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}
42. Connect the drive shaft (RH) to joint shaft. (MTX).
43. Apply the silicone sealant and install the engine front cover upper blind plug.
CAUTION:
Install the engine front cover upper blind plug before the applied silicone sealant starts to harden.
8—11 N·m {82—117 kgf·cm, 71—101 in·lbf}
44. Install a new engine front cover lower blind plug.
10—14 N·m {102—142 kgf·cm, 89—123 in·lbf}
45. Install the drive belt. (MZR 2.5).
46. Install the generator drive belt. (MZR 2.0).
47. Install the aerodynamic under cover No.2 and splash shield as a single unit..
48. Install the cylinder head cover..
49. Install the oil level gauge.
50. Install the ventilation hose.
51. Install the spark plugs..
52. Install the ignition coils..
53. Connect the wiring harness.
54. Install the plug hole plate..
55. Connect the negative battery cable..
56. Install the battery cover..
Oil Seal (Differential) Replacement [G66 M R]
1. On level ground, jack up the vehicle and support it evenly on safety stands.
2. Remove the aerodynamic under cover No.2..
3. Drain the oil from the transaxle..
4. Remove the front splash shield..
5. Separate the drive shaft and joint shaft from the transaxle..
6. Remove the oil seals u ...
Clutch Fluid Replacement/Air Bleeding [C66 M R]
CAUTION:
Do not allow clutch fluid get on a painted surface. Clutch fluid contains
properties which can dissolve the paint. If clutch fluid gets on a painted surface,
wash it off with water immediately and wipe the area off completely.
Do not mix different types of clutch fluid ...
Drive Shaft Inspection
1. Inspect the connections for any looseness.
If there is any malfunction, tighten or replace the applicable part.
2. Inspect the dust boot for damage and cracks.
If there is any malfunction, replace the applicable part.
3. Move the spline and joint up and down, left ...