Repair Procedures

Removal

1. Remove the engine cover(A).




2. Remove the front right wheel and tire.
3. Remove the right side cover.
4. Remove the drive belt(A), the idler(B) and the tensioner(C).





NOTE:
In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise.

5. Remove the timing belt upper cover(A).




6. Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover.
(No.1 cylinder piston at TDC)




7. Remove the engine mounting bracket.
(1) Sustain the engine oil pan with a jack.

CAUTION:
Put a wooden or rubber block between the jack and the engine oil pan.

(2) Remove the engine mounting bracket(A).




8. Remove the crankshaft damper pulley(A).




9. Remove the timing belt lower cover(A).




10. Remove the engine support bracket(A).





NOTE:
After removal, a small amount of engine coolant may drain from point (B).

11. Remove the timing belt auto tensioner(A).




12. Remove the timing belt(A).





NOTE:
Mark the direction of rotation on the timing belt.

13. Remove the tensioner arm assembly(A) and the idler(B).




14. Remove the crankshaft sprocket.

Installation

1. Install the crankshaft sprocket.
2. Install the tensioner arm assembly(A) and the idler(B).

Tightening torque
Tensioner arm bolt :
34.3 - 53.9Nm(3.5 - 5.5kgf.m, 25.3 - 39.8lb-ft)
Idler pulley bolt :
49.0 - 58.8Nm(5.0 - 6.0kgf.m, 36.2 - 43.4lb-ft)





3. Ensure the timing marks on the camshaft and the crankshaft sprockets.




4. Install the timing belt.
Crankshaft sprocket(A) -> Idler(B) -> Bank 2 exhaust camsprocket(C) -> Water pump pulley(D) -> Bank 1 exhaust camsprocket(E) -> Tensioner pulley(F).




5. Install the timing belt auto tensioner.
(1) Make the tensioner stand for about five minutes before installing.
(2) Press the rod with the weight, 150 - 200N.
(3) If the rod is stiff, insert a set-pin with pressing the rod slowly. If not, press the rod 2 - 3 times from the maximum length to 2.9mm(the position in which the two holes of the rod and the body can be at one).
(4) Check for stiffness. If there is, insert a set-pin and other wise, replace the auto-tensioner.





NOTE:
- Do not lay down the auto tensioner.
- Do not compress the rod suddenly. Compress the rod with the weight less than 4000N.
- When reinstalling the auto tensioner, ensure proper orientation.
- Do not press the rod any more when its projection from the body is 2.5mm.
- Keep the auto-tensioner stand at room temperature in winter.

(5) Install the auto tensioner(A) to the front case with the set-pin inserted.

Tightening torque
19.6 - 26.5Nm(2.0 - 2.7kgf.m, 14.5 - 19.5lb-ft)





6. Remove the auto tensioner set-pin.
7. Check the tension of the timing belt.
(1) Turn the crankshaft 2 revolutions clockwise, and set the number one cylinder to TDC.
After 5minutes, measure the length of the projected rod.

Specification
5 - 7mm(0.1969 - 0.2756in.)





(2) Ensure the locations of the timing marks for each sprocket.
8. Install the engine support bracket(A).

Tightening torque
58.8 - 68.6Nm(6.0 - 7.0kgf.m, 43.4 - 50.6lb-ft)






CAUTION:
- Check for the length of the bolts.(Upper-2EA/Lower-1EA).
- Use a torque wrench by all means.

9. Install the timing belt lower cover.

Tightening torque
9.8 - 11.8Nm(1.0 - 1.2kgf.m, 7.8 - 8.7lb-ft)






NOTE:
Align the holes of the bolts by pushing the left timing belt lower cover to left a little bit.

10. Install the crankshaft damper pulley(A).

Tightening torque
166.7 - 176.5Nm(17.0 - 18.0kgf.m, 123.0 - 130.2lb-ft)





11. Install the engine mounting bracket(A).

Tightening torque
63.7 - 83.4Nm(6.5 - 8.5kgf.m, 47.0 - 61.5lb-ft)





12. Install the timing belt upper cover(A).

Tightening torque
9.8 - 11.8Nm(1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)





13. Install the drive belt tensioner(C).

Tightening torque
34.3 - 53.9Nm(3.5 - 5.5kgf.m, 25.3 - 39.8lb-ft)


14. Install the drive belt idler and the drive belt(A).

Tightening torque
34.3 - 53.9Nm(3.5 - 5.5kgf.m, 25.3 - 39.8lb-ft)





15. Install the right side cover.
16. Install the front right wheel and tire.
17. Install the engine cover(A).

Tightening torque
7.8 - 11.8Nm(0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)