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In-vehicle Repair|Oil Pan > < Timing Chain

Ka 1997 (09.1996-)

Engine - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam) - Cylinder Head Ka 1997 (09/1996-)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Socket, Cylinder Head Bolt

303-392 (21-167)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Trolley jack

Removal

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Remove the intake manifold.
    For additional information, refer to Intake Manifold - in this section.
  1. Remove the valve cover.
    For additional information, refer to Valve Cover - in this section.
  1. Drain the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling.

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    NOTE:
    NOTE:The camshaft sprocket timing mark must be in the 12 o’clock position.
    NOTE:
    NOTE:Mark the position of the timing chain.
    Rotate the crankshaft until piston No. 1 is at top dead center (TDC).

  1. Disconnect the heated oxygen sensor (HO2S) electrical connector.

  1. Remove the exhaust manifold upper heat shield.

  1. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

  1. Using the special tool, disconnect the coolant hoses from the coolant control housing.

  1. Remove the timing chain hydraulic tensioner.

  1. Detach the oil level indicator tube from the cylinder head.

  1. Remove the exhaust manifold retaining nuts in the sequence shown (engine shown removed for clarity).
    • Discard the gasket and the retaining nuts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the exhaust manifold lower heat shield (engine shown removed for clarity).

  1. Remove the exhaust manifold lower retaining nuts.
    • Detach the exhaust manifold from the cylinder head.
  1. Lower the vehicle.

  1. Detach the power steering fluid reservoir from the wheel housing and position it to one side
  1. Using a trolley jack, support the engine and transaxle assembly.
Vehicles with 1.3L engine
  1. Remove the engine front mount.
    • Discard the nuts.

  1. Remove the engine front mount bracket retaining bolt.
Vehicles with 1.6L engine
  1. Remove the engine front mount.
    • Discard the nuts.

  1. Remove the engine front mount bracket retaining bolt.
All vehicles
  1. NOTE:
    NOTE:Use a suitable piece of wire to prevent the timing chain from dropping into the cylinder block.
    Using the special tool, remove the camshaft sprocket.

  1. NOTE:
    NOTE:Loosen the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Guide the timing chain through the cylinder head and secure it to the cylinder block.
    • Discard the gasket.
    • Discard the cylinder head bolts.

Installation

All vehicles
  1. NOTE:
    NOTE:Install new cylinder head bolts.
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Guide the timing chain through the cylinder head and secure it to the cylinder head.
    Using the special tool, install the cylinder head.
    • Tighten the bolts in the sequence shown in four stages.
    • Stage 1: Tighten bolts 1 through 10 to 40 Nm.
    • Stage 2: Tighten the front two (M8) bolts to 15 Nm.
    • Stage 3: Tighten the front two (M8) bolts to 45 degrees.
    • Stage 4: Tighten bolts 1 through 10 to 120 degrees.

  1. NOTE:
    NOTE:The camshaft sprocket timing mark must be in the 12 o´clock position.
    NOTE:
    NOTE:The camshaft sprocket timing mark and the marked links of the timing chain must line up.
    Install the camshaft sprocket and the timing chain.

  1. Using the special tool, tighten the camshaft sprocket retaining bolt.
Vehicles with 1.3L engine
  1. Install the engine front mount bracket retaining bolt.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.
Vehicles with 1.6L engine
  1. Install the engine front mount bracket retaining bolt.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.
All vehicles
  1. Remove the trolley jack.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts.
    Attach the exhaust manifold to the cylinder head (engine shown removed for clarity).
    • Tighten the retaining nuts in the sequence shown in two stages.
    • Stage 1: 15 Nm
    • Stage 2: 20 Nm
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the exhaust manifold lower retaining bolts.

  1. Install the exhaust manifold lower heat shield.
  1. Lower the vehicle.

  1. Attach the oil level indicator tube to the cylinder head.

  1. Install the timing chain hydraulic tensioner.

  1. Attach the power steering fluid reservoir to the wheel housing.

  1. Using the special tool, connect the coolant hoses to the coolant control housing.

  1. Connect the engine coolant temperature (ECT) sensor electrical connector.

  1. Install the exhaust manifold upper heat shield.

  1. Connect the heated oxygen sensor (HO2S) electrical connector.
  1. Install the valve cover.
    For additional information, refer to Valve Cover - in this section.
  1. Install the intake manifold.
    For additional information, refer to Intake Manifold - in this section.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling.

In-vehicle Repair|Oil Pan > < Timing Chain