REMOVAL AND INSTALLATION







Removal steps
<<A>>
>>D<<
1.
Timing chain tensioner

>>D<<
2.
Tensioner lever

>>D<<
3.
Timing chain guide

>>D<<
4.
Crankshaft key

>>C<<
5.
Crankshaft sprocket

>>B<<
6.
Crankshaft gear

>>B<<
7.
Balancer shaft drive housing and gear

>>B<<
8.
Trust plate

>>B<<
9.
Coupling

>>A<<
10.
Balancer unit bolt

>>A<<
11.
Balancer unit *1
note *1:The balancer unit must not be overhauled for the assembly assurance.

REMOVAL SERVICE POINT



<<A>> TIMING CHAIN TENSIONER REMOVAL



1.Push the tensioner lever by hand and push in the plunger of the timing chain tensioner until it hits the bottom. Then, insert a hard wire (piano wire or the like) of Φ1.0 or hexagonal bar wrench (1.0 mm) into the fixing hole of the plunger.
warning If the timing chain tensioner set pin (fixed wire) suddenly comes off the timing chain tensioner, it is very dangerous because the plunger jumps out.
2.Remove the timing chain tensioner.
note At that time, the timing chain cannot be removed.

INSTALLATION SERVICE POINTS



>>A<< BALANCER UNIT / BALANCER UNIT BOLT INSTALLATION


1.Apply the appropriate and minimum amount of engine oil to the balance unit bolt thread portion and the lower portion of the flange.

2.Install the balancer unit to the lower crankcase and tighten them to the tighten torque of 20 N·m in the order shown in the illustration.

3.Use Special Tool Angle Gauge (MB991614) to tighten them an additional 60°.

>>B<< BALANCER SHAFT DRIVE HOUSING AND GEAR / COUPLING / TRUST PLATE / CRANKSHAFT GEAR INSTALLATION



1.Use a rag to wipe off the dirt on the crankshaft gear and the crankshaft. Remove the grease on the portion shown in the illustration.
note Remove the grease in order that adhered oil cannot decrease the wear coefficient of the pressed area.

2.Apply the appropriate and minimum amount of engine oil to the thrust plate, as shown in the illustration.
3.Install all of these so that the thrust plate face where the engine oil is applied can face toward the balancer shaft drive housing & gear.
4.Install all of these aligning all the timing marks.
5.When tightening the balancer shaft drive housing and the gear, tighten the bolt shown in the illustration first.



>>C<< CRANKSHAFT SPROCKET INSTALLATION



Use a rag to wipe off the dirt on the crankshaft sprocket and the crankshaft. Remove the grease on the portion shown in the illustration.
note Remove the grease in order that adhered oil cannot decrease the wear coefficient of the pressed area.

>>D<< CRANKSHAFT KEY / TIMING CHAIN GUIDE / TENSIONER LEVER / TIMING CHAIN TENSIONER INSTALLATION



1.Install all of these so that the centres of two location marks of the crankshaft sprocket can align with the border line between the cylinder block and the lower crank case.
2.Install the crankshaft key.
note This position becomes the No.1 cylinder compression top dead centre finally.
3.Align the timing mark of the camshaft and the timing mark of the crankshaft sprocket with the link plate of the timing chain to install the timing chain.
4.Tighten the chain guide to the specified torque of 11 ± 3 N·m.
5.Tighten the tensioner lever to the specified torque of 24 ± 3 N·m. After the installation, check that the turn direction has flexibility at the bolt support point.
6.Tighten the timing chain tensioner to the specified torque of 11 ± 3 N·m.

7.
warning If the timing chain tensioner set pin (fixed wire) suddenly comes off the timing chain tensioner, it is very dangerous because the plunger jumps out.
After that, pull out the set pin (fixed wire) to give tension to the timing chain.
Check that the timing chain tensioner plunger fits securely into the tensioner lever groove.
Check that the timing chain link securely engages with the gear without going beyond.
Check that the timing chain does not deviate from the chain guide and the tensioner lever chain running surface.
8.Check that each timing mark aligns with two link plates of the timing chain.