Table of contents: Removal ↓ Installation ↓
1. Cylinder block
2. Chain guide
3. Right camshaft drive sprocket
4. Timing chain tensioner
5. Tensioner shoe
6. Front crankcase
7. Crankshaft pulley
8. Oil pump drive spacer sleeve
9. Crankshaft sprocket
10. Chain tensioner
11. Drive chain
12. Left camshaft drive sprocket
Removal
CAUTION: After removing the timing chain, do not turn the crankshaft and camshaft separately to avoid damaging the pistons and valves.
1. Release the pressure in the fuel system (see chapter "Fuel injection system").
2. Remove the lower engine splash guards.
3. Remove the right wheel and engine side splash guard.
4. Drain the coolant from the radiator and cylinder block.
5. Remove the radiator.
6. Disconnect the air duct from the intake manifold.
7. Remove the drive belts and water pump pulley.
8. Remove the generator and power steering pump.
9. Disconnect vacuum hoses, fuel lines, wires, etc.
10. Remove all spark plugs.
11. Remove the cylinder head cover and oil separator. The sequence of loosening the bolts is shown in the figure.
12. Remove the intake manifold brackets.
13. Remove the oil filter and power steering pump brackets.
14. Set the piston of the 1st cylinder to TDC of the compression stroke.
The timing marks on the camshaft sprockets must be positioned as shown in the figure.
15. Remove the chain tensioner.
16. Remove the ignition distributor. Do not turn the rotor with the distributor removed.
17. Remove the chain guide.
18. Remove the camshaft drive sprockets, holding the shafts from turning (there are special hexagons on the shaft journals near the sprockets).
19. Remove the camshaft bearing caps, shafts, oil pipes and partition. Loosen the cap bolts in the sequence shown in the figure.
20. Remove the starter.
21. Disconnect the water hoses from the cylinder block and radiator.
22. Disconnect the knock sensor connector.
23. Remove the outer cylinder head bolts.
24. Loosen the cylinder head mounting bolts. Loosen the bolts in two or three steps, in the sequence shown in the figure.
25. Remove the cylinder head together with the intake and exhaust manifolds.
26.Remove the oil pan (see the relevant section of this chapter).
27. Remove the oil receiver.
28. Remove the crankshaft pulley.
29. Place a transmission jack under the crankshaft main bearings.
30. Remove the front engine mount.
31. Remove the front crankcase and the oil pump drive spacer sleeve.
32. Remove the tensioner shoe and chain guide, and then the chain itself.
Installation
1. Install the crankshaft sprocket. The marks on the sprocket should point away from the engine.
2. Set the crankshaft to the position where the piston of the 1st cylinder is at TDC of the compression stroke. The key should be on top. Put the drive chain on the crankshaft sprocket, aligning the timing marks.
The timing marks on the chain have the following colors:
1 - golden; 2, 3 - silver.
3. Install the tensioner shoe and tension damper.
4. Before installing the front crankcase, remove all traces of old sealant from the mounting surfaces of the crankcase and cylinder block.
Apply a continuous bead of sealant to the front crankcase as shown. Make sure the new front crankshaft oil seal is installed in the correct direction.
5. Install the oil pump drive spacer sleeve and front crankcase.
6. Remove the sealant squeezed out from the joints of the front crankcase with the cylinder block at the top and bottom.
7. Install the front engine mount.
8. Install the crankshaft pulley.
9. Set the piston of the first cylinder to TDC of the compression stroke according to the marks on the pulley (see subsection "Removal").
10. Install the oil receiver and oil pan.
11. Before installing the cylinder head gasket, apply sealant to the areas shown in the figure.
12. Install the cylinder head together with the intake and exhaust manifolds.
Before installation, apply engine oil to the cylinder head bolt threads and their mounting surfaces.
Make sure there are washers between the bolts and the cylinder head.
CAUTION: Cylinder head bolts can be reused if length A does not exceed 158.2 mm.
Tightening sequence:
a) Tighten all bolts in the sequence shown in the figure to a torque of 39 Nm.
b) Tighten all bolts to 78 Nm.
c) Loosen all bolts completely.
d) Tighten all bolts to 34-44 Nm.
e) Tighten all bolts to an angle of 90-95°. If you do not have a spanner with a protractor, mark the sides of the bolts facing the front of the engine, then tighten the bolts approximately to the required angle.
f) Tighten all bolts an additional 90-95°. When using the second tightening method, the marks on the bolts should be directed towards the rear of the engine. Angles of 90° are preferred, an angle of 95° is the maximum permissible deviation.
Do not turn the bolts 180-190° at once.
13. Tighten the outer cylinder head bolts.
14. Connect the removed water hoses and the knock sensor connector.
15. Install the starter.
16. Apply sealant to the left camshaft rear bearing cover, after removing any traces of old sealant from the cover and cylinder head.
17. Install the camshafts, positioning them as shown in the figure: the pin of the left shaft should be located on top, the pin of the right shaft at approximately a 60° angle to the vertical.
Before installing the shafts, lubricate their journals and cams with engine oil.
18. Install the bearing caps, arranging them as shown in the figure.
Before installing the caps, apply engine oil to the threads and bolt seating surfaces.
Bolt tightening sequence:
- a) For the right shaft, tighten bolts 9-10, then bolts 1-8 to 2 Nm in the sequence shown in the figure. For the left shaft, tighten bolts 11-12, then bolts 1-10 to 2 Nm in the sequence shown in the figure.
- b) Tighten the bolts in the same sequence to 6 Nm.
- c) Tighten bolts A-B, DF to 9.8-11.8 Nm, bolt C to 18-25 Nm in the above sequence.
For SR20DE engines installed on European models from 04.96, tighten bolts A and B to 9.8-11.8 Nm, bolt C to 18-25 Nm in the sequence specified above.
19. Install the camshaft drive sprockets, aligning the marks on the chain with the marks on the sprockets.
Before tightening the bolts, apply engine oil to their threads and seating surfaces.
Tighten the bolts to 137-157 Nm. When tightening, hold the camshafts by the hexagons near the front journals.
20. Install the drive chain guide.
21. Install the ignition distributor. The camshaft should be in the position shown in the figure.
Make sure that the piston of the 1st cylinder is set to TDC and the position of the distributor rotor corresponds to the ignition timing in the 1st cylinder.
22. Install the chain tensioner. To do this, press the lock and push the plunger so that you can put the hook on the pin. After installing the tensioner, the plunger will be automatically released. Arrow A should point to the front of the engine.
23. Install the oil filter, power steering pump and intake manifold brackets.
24. Apply sealant to the cylinder head cover gasket and the cylinder head in the areas shown in the figure. Before doing this, carefully remove any remaining old sealant.
25. Install the cylinder head cover and oil separator.
Tightening sequence:
- a) Tighten nuts 1-10-11-13-8 in this sequence to a torque of 4 Nm. For SR20DE engines installed in European models from 04.96, the tightening torque is 8-10 Nm.
- b) Tighten nuts 1-13 to a torque of 8-10 Nm in the sequence shown in the figure.
26. Screw in the spark plugs.
27. Connect all vacuum hoses, fuel lines and wires.
28. Install the power steering pump and generator.
29. Install the water pump pulley and drive belts.
30. Connect the air duct to the intake manifold.
31. Install the radiator, connect the water hoses and fill the cooling system with liquid (see chapter "Maintenance").
32. Install the engine mudguards and right wheel.