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    2008 Honda Civic EX 1.8L MFI SOHC 4cyl

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    Suzuki Aerio, Verona 2002-06

    Timing Chain & Sprockets

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    Removal & Installation



    2.0L And 2.3L Engines


    Click image to see an enlarged view

    Fig. Exploded view of second timing chain and related components-2.0L and 2.3L engines



    Click image to see an enlarged view

    Fig. Exploded view of first timing chain and related components-2.0L and 2.3L engines

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove engine assembly from vehicle.
    4.  
    5. Remove oil pan.
    6.  
    7. Remove cylinder head cover.
    8.  
    9. Remove timing chain cover as follows:
      1. Remove crankshaft pulley bolt. To lock crankshaft pulley, use special tool 09917-68221 (camshaft pulley holder).
        NOTE
        Be sure to use the following bolts instead of pins for fixing special tool to crankshaft pulley. Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Strength: 7T

      2.  
      3. Remove crankshaft pulley. To remove crankshaft pulley, use special tools 09944-36011 and 09926-58010 (steering wheel remover and bearing puller attachment).
      4.  
      5. Remove A/C compressor bracket.
      6.  
      7. Remove alternator belt idler pulley, water pump pulley and alternator belt tensioner.
      8.  
      9. Remove timing chain cover bolts and nut.

        Click image to see an enlarged view

        Fig. Turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets as shown-2.0L and 2.3L engines

      10.  

    10.  
    11. For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets as shown in figure.
    12.  
    13. Remove second timing chain as follows:
      1. Turn crankshaft to meet following conditions.

        Key (I) on crankshaft is positioned as shown.
         
        Arrow mark on idler sprocket (II) points upward.
         
        Marks on sprockets (III) match with marks on cylinder head. Note that this step must be followed for reinstallation of timing chain.
         

      2.  
      3. Remove timing chain tensioner adjuster No.2 and gasket. To remove them, slacken second timing chain by turning intake camshaft counterclockwise a little while pushing back pad.
      4.  
      5. Remove intake and exhaust camshaft timing sprocket bolts. To remove them, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
      6.  
      7. Remove camshaft timing sprockets and second timing chain.
        WARNING
        After second timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.

      8.  

    14.  
    15. Remove timing chain guide No.1.
    16.  
    17. Remove timing chain tensioner adjuster No.1.
    18.  
    19. Remove timing chain tensioner.
    20.  
    21. Remove idler sprocket and first timing chain.
    22.  
    23. Remove crankshaft timing sprocket.
    24.  

    To install:

    1. Check that match mark on crankshaft timing sprocket is in match with timing mark on lower crankcase.
    2.  
    3. Install crankshaft timing sprocket as shown in figure.
    4.  
    5. Apply oil to bush of idler sprocket and install idler sprocket and sprocket shaft.
    6.  
    7. Install first timing chain by aligning dark blue plate of first timing chain and match mark on idler sprocket.
    8.  
    9. Bring yellow plate of first timing chain into match with match mark on crankshaft timing sprocket.
    10.  
    11. Apply engine oil to sliding surface of timing chain tensioner and then install it as shown in figure. Tighten tensioner nut to 18 ft. lbs. (25 Nm).
    12.  
    13. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch and body. After inserting it, check to make sure that plunger will not come out.
    14.  
    15. Install timing chain tensioner adjuster No.1. Tighten the timing chain tensioner adjuster No. 1 bolt to 8 ft. lbs. (11 Nm).
    16.  
    17. Pull out stopper from adjuster No.1.
    18.  
    19. Apply engine oil to sliding surface of timing chain guide No.1 and then install it. Tighten guide bolts to 6.5 ft. lbs. (9 Nm).
    20.  
    21. Check that dark blue and yellow plates of first timing chain are in match with match marks on sprockets respectively.
    22.  
    23. Install second timing chain as follows:
      1. Check that match mark on crank timing sprocket is in match with timing mark on lower crankcase.
      2.  
      3. Check that arrow mark on idler sprocket faces upward.
      4.  
      5. Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head.
      6.  
      7. Install second timing chain by aligning yellow plate of second timing chain and match marks on idler sprocket.
      8.  
      9. Install sprockets to intake and exhaust camshafts by aligning dark blue plate of second timing chain, match marks on intake sprocket and exhaust sprocket respectively.
        NOTE
        As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.

      10.  
      11. Install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary. Tighten the camshaft timing sprocket bolt to 57.5 ft. lbs. (80 Nm).
      12.  
      13. Push back plunger into tensioner body and hold it at the position by inserting stopper into body.
      14.  
      15. Install timing chain tensioner adjuster No.2 with new gasket. Tighten the timing chain tensioner adjuster No. 2 bolts to 8 ft. lbs. (11 Nm) and No. 2 nut to 33 ft. lbs. (45 Nm).
      16.  
      17. Pull out stopper from timing chain tensioner adjuster No.2.
      18.  
      19. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block.
      20.  
      21. Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
      22.  
      23. Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.

        Click image to see an enlarged view

        Fig. Sealant application on timing belt cover-2.0L and 2.3L engines

      24.  

    24.  
    25. Install timing chain cover. Reverse removal sequence to install timing chain cover noting the following points:
      1. Apply sealant -A- and -B- to area as shown.

        -A-: Sealant 99000-31250
         
        -B-: Sealant 99000-31140
         

      2.  
      3. Apply sealant amount to the following areas.

        -a-: 0.12 inches (3mm)
         
        -b-: 0.08 inches (2mm)
         
        -c-: 0.24 inches (6mm)
         
        -d-: 0.63 inches (16mm)
         
        -e-: 0.55 inches (14mm)
         
        -f-: 2.56 inches (65mm)
         
        -g-: 2.87 inches (73mm)
         
        -h-: 0.16 inches (4mm)
         

      4.  
      5. Apply engine oil to oil seal lip, then install timing chain cover. Tighten bolts and nut to 8 ft. lbs. (11 Nm).
        NOTE
        Before installing timing chain cover, check that pin is securely fitted.

      6.  

    26.  
    27. Install alternator belt idler pulley. Tighten nut to 30.5 ft. lbs. (42 Nm).
    28.  
    29. Install alternator belt tensioner. Tighten bolts to 18.5 ft. lbs. (25 Nm).
    30.  
    31. Install water pump pulley.
    32.  
    33. Install A/C compressor bracket (if equipped). Tighten bracket bolts to 40 ft. lbs. (55 Nm).
    34.  
    35. Install cylinder head cover with new gaskets and seal washers and tighten nuts to 8 ft. lbs. (11 Nm).
    36.  
    37. Install oil pan.
    38.  
    39. Install crankshaft pulley using pulley holder tool. Tighten the crankshaft pulley bolt to 108.5 ft. lbs. (150 Nm).
    40.  
    41. Install engine assembly.
    42.  
    43. Install all remaining components in the reverse order of the removal procedure.
    44.  

    2.5L Engine
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove the fuel pump fuse.
    4.  
    5. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
    6.  
    7. Disconnect the negative battery cable.
    8.  
    9. Drain the engine coolant, engine oil, transaxle oil and power steering oil.
    10.  
    11. Recover the refrigerant.
    12.  
    13. Remove the engine.
    14.  
    15. Remove the flex plate bolts and the flex plate.
    16.  
    17. Support the engine assembly with an engine stand.
    18.  
    19. Remove the intake manifold.
    20.  
    21. Remove the cylinder head cover.
    22.  
    23. Remove the drive belt.
    24.  
    25. Remove the oil pan.
    26.  
    27. Install the crankshaft pulley holder DW110-130-01 to the crankshaft pulley bolt.
      NOTE
      Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.

    28.  
    29. Remove the crankshaft pulley bolt using the crankshaft pulley installer/remover tool DW110-130-02.
    30.  
    31. Remove the engine mount bracket support.
    32.  
    33. Remove the water pump pulley.
    34.  
    35. Remove the drive belt automatic tensioner retaining bolts and the tensioner.
    36.  
    37. Remove the timing chain cover.
    38.  
    39. Remove 2 dowel rings for timing cover.
    40.  
    41. Remove the timing chain tensioner.
    42.  
    43. Remove the fixed timing chain guide.
    44.  
    45. Remove the timing chain lever.
    46.  
    47. Remove the top chain guide.
    48.  
    49. Remove the timing chain.
    50.  
    51. Remove the crankshaft sprocket and the woodruff key.
    52.  

    To install:

    Click image to see an enlarged view

    Fig. View of the timing chain and timing marks-2.5L engine

    1. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using camshaft sprocket holder DW110-150.
    2.  
    3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
    4.  
    5. Adjust the crankshaft using the crankshaft adjuster DW110-190.
    6.  
    7. Make sure the 3 timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, and crankshaft sprocket respectively.
    8.  
    9. Install the fixed timing chain guide and tighten the fixed timing chain guide bolts to 13-16 ft. lbs. (18-22 Nm).
    10.  
    11. Install the timing chain lever and tighten the timing chain lever bolt to 13-16 ft. lbs. (18-22 Nm).
    12.  
    13. Install the timing chain tensioner and tighten the timing chain tensioner bolt to 13-16 ft. lbs. (18-22 Nm).
    14.  
    15. Install the top chain guide and tighten the top chain guide bolt to 80-97 inch lbs. (9-11 Nm).
    16.  
    17. Install 2 dowel rings.
    18.  
    19. Apply the liquid gasket (Loctite® 5900-M8585) on the timing chain cover. Install the timing chain cover install guide pin DW110-140 and position the timing chain cover.
      NOTE
      Be sure the applied liquid gasket is not damaged when installing the timing chain cover.

    20.  
    21. Install the timing chain cover. Tighten the timing chain cover bolt (center) to 13-16 ft. lbs. (18-22 Nm); and tighten the remaining timing chain cover bolts to 53-89 inch lbs. (6-10 Nm).
    22.  
    23. Install the drive belt automatic tensioner and tighten the drive belt automatic tensioner retaining bolt to 15-22 ft. lbs. (20-30 Nm).
    24.  
    25. Install the water pump pulley and tighten the water pump pulley bolts to 71-106 inch lbs. (8-12 Nm).
    26.  
    27. Install the engine mount bracket support and tighten the engine mount bracket support bolts to 18-23 ft. lbs. (25-31 Nm).
    28.  
    29. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the crankshaft pulley holder DW110-130-01 and the crankshaft pulley installer/remover tool DW110-130-02. Tighten the crankshaft pulley bolt to 369-443 ft. lbs. (500-600 Nm).
    30.  
    31. Install the oil pan.
    32.  
    33. Install the cylinder head cover along with a new gasket. Tighten the cylinder head cover bolts to 106-124 inch lbs. (12-14 Nm).
    34.  
    35. Install the intake manifold.
    36.  
    37. Install the flex plate and tighten the flexible plate bolts to 52-59 ft. lbs. (70-80 Nm).
    38.  
    39. Install the transaxle to the engine assembly.
    40.  
    41. Install the engine and transaxle assembly.
    42.  
    43. Install all remaining components in the reverse order of the removal procedure.
    44.  

    8-Cylinder Engines
    1. Disconnect the battery negative cable.
      CAUTION
      Remove ignition key.

    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the accessory drive belt, refer to Accessory Drive Belts removal and installation.
    6.  
    7. Remove the right front wheel.
    8.  
    9. Remove crankshaft damper protective cover nuts.
    10.  
    11. Push the protection towards the crankshaft damper.
    12.  
    13. Remove the center bolt using special tool 999 7196.
    14.  
    15. Install 999 7198 in the center hole of the crankshaft.
    16.  
    17. Pull off the crankshaft damper.
    18.  
    19. Remove the alternator.
    20.  
    21. Remove right engine pad
    22.  
    23. Remove the right-hand engine pad/bracket.
    24.  
    25. Disconnect the power steering pump. Place the power steering pump to one side.
    26.  
    27. Remove the bolt and clamp for the power steering hose.
    28.  
    29. Remove the pulley from the water pump.
    30.  
    31. Remove the engine bracket and idler pulley.

      Click image to see an enlarged view

      Fig. Front cover bolts-V8

    32.  
    33. Remove the 25 bolts and the front cover. Discard the gaskets.
      NOTE
      Cover the hole in oil pan using a piece of paper.

    34.  
    35. Use position setting tool 999 7235 to align the position on the crankshaft with the guide on the engine block.

      Click image to see an enlarged view

      Fig. Position setting tool 999 7235-V8 engine



      Click image to see an enlarged view

      Fig. Position setting tool 999 7236-V8 engine

    36.  
    37. Install position setting tool: 999 7236.
    38.  
    39. Remove the position setting tool: 999 7235.
    40.  
    41. Lock the chain tensioner using a drift.

      Click image to see an enlarged view

      Fig. Timing chain tensioners-V8

    42.  
    43. Remove the 2 M6 bolts for the chain tensioner.
    44.  
    45. Remove the chain tensioner.
    46.  
    47. Remove the 2 rails.
    48.  
    49. Remove the timing chain.
    50.  
    51. Remove worn chain sprockets.
    52.  

    To install:

    Click image to see an enlarged view

    Fig. Timing chain alignment marks-V8


    NOTE
    Adjust the color marking on the timing chain to the marking on the gear.

    1. Install the timing chain, sprockets, and both rails.
    2.  
    3. Install the chain tensioner.
    4.  
    5. Remove the drift from the chain tensioner.
    6.  
    7. Minimize the slack of the chain by turning the crankshaft slightly.
      NOTE
      The front cover must be cleaned before installing. Use a razor blade or plastic scraper.



      Click image to see an enlarged view

      Fig. Liquid gasket application points-V8

    8.  
    9. Apply liquid gasket 307 57050 as illustrated. The bead diameter must be greater than 0.039 inch (1mm).
      NOTE
      Install the front plate within 5 minutes (curing time for liquid gasket).

    10.  
    11. Fold the front panel in at the lower edge.
    12.  
    13. Install the 23 M8 bolts for the front side and tighten to 18 ft. lbs. (24 Nm).
    14.  
    15. Install the 2 M8 bolts for the oil sump and tighten to 18 ft. lbs. (24 Nm).
    16.  
    17. Install the engine bracket and the idler pulley.
      NOTE
      The washer must be correctly installed.

    18.  
    19. Install the pulley for the water pump.
    20.  
    21. Install the power steering pump.
    22.  
    23. Install the hose clamp and the bolt.
    24.  
    25. Install the front bolt for the alternator and tighten to 18 ft. lbs. (24 Nm).
    26.  
    27. Install lifting beam tool 999 5716, converted with the addition of 999 7070 and 999 5460.
    28.  
    29. Remove tool 999 5550.
    30.  
    31. Install the right-hand engine pad/bracket.
      NOTE
      The crankshaft flange must be cleaned.

    32.  
    33. Clean the surface for the sealing ring on the crankshaft damper with cloth 951 1024.
      NOTE
      If necessary, replace the front crankshaft seal.

    34.  
    35. Install tool 999 7196, drift: 999 7198 and press in the crankshaft damper to its limit. Position using the old center bolt.
    36.  
    37. Remove the center bolt.
    38.  
    39. Insert a new bolt for the crankshaft damper and tighten 133 ft. lbs. (180 Nm).
    40.  
    41. Remove tool 999 7196.
    42.  
    43. Install the protective cover.
    44.  
    45. Install the camshaft covers.
    46.  
    47. Install the accessory drive belt tensioner.
    48.  
    49. Install the right front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm).
    50.  
    51. Start the engine and run the engine to normal operating temperature.
    52.  
    53. Check for leakage. Fill fluids as necessary.
    54.  

     
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