Repair Procedures
Removal
CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid misconnection.
1. Disconnect the battery negative terminal.
2. Remove the engine cover (A).
3. Remove the air cleaner assembly.
(1) Remove the air duct (B).
(2) Disconnect the breather hose (C) and the intensifier hose (D).
(3) Disconnect the air intake hose and then remove the air cleaner assembly (E).
4. Remove the under cover and side cover.
5. Disconnect the ignition coil connectors (A) and the exhaust CMP (Camshaft position sensor) connector (B).
6. Disconnect the PCV (Positive crankcase ventilation) hose (A).
7. Remove the ignition coils (A).
8. Remove the cylinder head cover (A).
9. Remove the air compressor lower bolts.
10. Remove the air compressor bracket (A).
11. Drain the engine oil.
12. Remove the oil pan (A). Insert the blade of SST (09215-3C000) between the ladder frame and oil pan. Cut off applied sealer and remove the lower oil pan.
NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not use the SST as a prybar. Hold the tool in position (on gasket line) and tap in with a light hammer.
- Be careful not to damage the contact surfaces of ladder frame and lower oil pan.
13. Install the jack to the edge of ladder frame.
NOTE:
Insert the wooden block between ladder frame and jack.
14. Disconnect the ground cable, and then remove the engine mounting bracket (A).
15. For release the tension, turn the drive belt tensioner counterclockwise then remove the drive belt (A).
16. Remove the idler (A) and drive belt tensioner (B).
CAUTION:
The tensioner pulley bolt has left handed threads.
17. Remove the water pump pulley (A), crankshaft pulley (B) and engine support bracket (C).
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3K000) to hold the ring gear after removing the starter.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
18. Remove the timing chain cover (A) by gently prying between the timing chain cover and the cylinder block.
CAUTION:
Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
19. The key of crankshaft should be aligned with the mating face of main bearing cap. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.
NOTE:
Before removing the timing chain, mark the timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
20. Install a set pin after compressing the timing chain tensioner.
21. Remove the timing chain tensioner (A) and timing chain tensioner arm (B).
22. Remove the timing chain.
23. Remove the timing chain guide (A).
24. Remove the timing chain oil jet (A).
25. Remove the crankshaft chain sprocket (B).
26. Remove the balance shaft chain.
Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the CVVT sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage.
Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.
Drive belt, Idler, Pulley
1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.
2. Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necessary.
3. Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necessary.
Installation
1. Install the balance shaft chain.
2. Install the crankshaft chain sprocket (B).
3. Install the timing chain oil jet (A).
Tightening torque:
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
4. Set the crankshaft so that the key (A) of crankshaft will be aligned with the mating surface of main bearing cap. Put the intake and exhaust camshaft assembly so that the TDC marks (B) of the intake and exhaust CVVT sprockets will be aligned with the top surface of cylinder head. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.
5. Install the timing chain guide (A).
Tightening torque:
9.8 - 11.6N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
6. Install the timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket (A) -> Timing chain guide (B) -> Intake CVVT sprocket (C) -> Exhaust CVVT sprocket (D).
NOTE:
The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.
7. Install timing chain tensioner arm (B).
Tightening torque:
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
8. Install timing chain auto tensioner (A) and remove set pin.
Tightening torque:
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
9. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
10. Install timing chain cover.
(1) Using a gasket scraper to remove all the old gasket material from the gasket surfaces.
(2) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and etc.
(3) Before assembling the timing chain cover, the liquid sealant Loctite 5900H or THREE BOND 1217H should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.
Bead width:3.0mm (0.12in.)
(4) After applying liquid sealant Loctite 5900H on timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.
Bead width:3.0mm (0.12in.)
(5) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
Tightening torque:
M6: 7.84 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
M8: 18.6 - 22.5N.m (1.9 - 2.3kgf.m, 13.7 - 16.6lb-ft)
CAUTION:
Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
11. Install the engine support bracket (C).
Tightening torque:
M10 : 39.2 - 44.1N.m(4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)
M8 : 19.6 - 24.5N.m(2.0 - 2.5kgf.m, 14.5 - 18.1lb-ft)
12. Install the crankshaft pulley (B).
Tightening torque :
166.6 - 176.4N.m (17.0 - 18.0kgf.m, 122.9 - 130.1lb-ft)
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3K000) to hold the ring gear after removing the starter.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
13. Install the water pump pulley (A).
Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
14. Install the drive belt tensioner (B) and tensioner pulley.
Tightening torque :
53.9 - 63.7N.m (5.5 - 6.5kgf.m, 39.7 - 47.0lb-ft)
15. Install the idler pulley (A).
Tightening torque :
53.9 - 63.7N.m (5.5 - 6.5kgf.m, 39.7 - 47.0lb-ft)
CAUTION:
Tensioner pulley bolt is left - handed screw.
16. Install the air compressor bracket (A).
Tightening torque :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 13.7 - 14.5lb-ft)
17. Install the compressor lower bolts.
Tightening torque :
20.0 - 33.0N.m (2.04 - 3.36kgf.m, 14.8 - 24.3lb-ft)
18. Install the drive belt (A).
Crankshaft pulley -> A/C pulley -> Alternator pulley -> Idler pulley-> P/S pump pulley -> Idler pulley -> Water pump pulley -> Tensioner pulley.
Rotate the auto tensioner counter - clockwise. With the tensioner turned, install the drive belt on auto tensioner and then release the tensioner.
19. Install the engine mounting bracket (A) and connect the ground cable.
Tightening torque :
Bolts (B) & Nut (C) : 63.8 - 83.4 N.m (6.5 - 8.5 kgf.m, 47.0 - 61.5 lb-ft)
Nut (D) : 78.5 - 107.9 N.m (8.0 - 11.0 kgf.m, 57.9 - 79.6 lb-ft)
20. Install the oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant Loctite 5900H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied.
Sealant :Loctite 5900H or equivalent
Bead width :3.0mm (0.12in.)
CAUTION:
- When applying sealant gasket, sealant must not protrude into the inside of the oil pan.
- To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
(3) Install oil pan. Uniformly tighten the bolts in several passes.
Tightening torque
M9 (B) : 30.4 - 34.3N.m (3.1 - 3.5kgf.m, 22.4 - 25.3lb-ft)
M6 (C) : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
After assembly, wait at least 30 minutes before filling the engine with oil.
NOTE:
Always use a new drain bolt gasket.
21. Install cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(2) After applying sealant, it should be assembled within 5 minutes.
Bead width :2.5mm (0.1in.)
(3) Install the cylinder head cover bolts in the following sequence.
Tightening torque
1st step: 3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
2nd step: 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
CAUTION:
- Do not reuse cylinder head cover gasket.
- The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
22. Install the ignition coils (A).
Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.4 lb-ft)
23. Connect the PCV (Positive crankcase ventilation) hose (A).
24. Connect the ignition coil connectors (A) and the exhaust CMP (Camshaft position sensor) connector (B).
25. Install the under cover and side cover.
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
26. Install the air cleaner assembly.
(1) Install the air cleaner assembly (E) and then connect the air intake hose.
Tightening torque
Hose clamp bolt :
2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)
Air cleaner assembly bolts :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
(2) Connect the breather hose (C) and the intensifier hose (D).
(3) Install the air duct (B).
27. Install the engine cover (A).
28. Connect the battery negative terminal.