Repair Procedures

alternator



Removal

Engine removal is not required for this procedure.
1. Loosen the water pump pulley bolt and the drive idler mounting bolt.
2. Loosen the alternator tension adjusting bolt(A) to loosen tension.




3. Remove the alternator drive belt(A).




4. Remove the alternator(A). .




5. Remove the RH front wheel.
6. Remove the engine mounting bracket(A).





NOTE:
Support the engine with a jack not to be tilted.

7. Remove the alternator bracket(B).
8. Remove the engine support bracket(A).




9. Remove the water pump pulley(A).




10. Remove the water pump(A).




11. Remove the drive belt idler(A).




12. Disconnect the ignition coil connector(A) and the breather hose(B).




13. Disconnect the positive crankcase ventilation(PCV) hose(A) and PCSV hose(B).




14. Remove the ignition coils(A).




15. Remove the cylinder head cover(A) with its gasket(B).




16. Remove side cover.




17. Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.




18. Remove the crankshaft bolt(B) and crankshaft pulley(A).




19. Remove the timing chain cover(A).




20. Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No.1 cylinder be positioned at TDC.
(1) Check the dowel pin of the crankshaft for facing upside of the engine at this moment.

CAUTION:
Put paint marks on the timing chain links(3 places) that meet with the timing marks of the camshaft sprockets(In, Ex : 2) and the crankshaft sprocket.




21. Remove the hydraulic tensioner(A).





CAUTION:
Before removing the tensioner, fix the piston of the tensioner with a pin through the hole(B) at TDC.

22. Remove the timing chain tensioner arm(A) and guide(B).




23. Remove the timing chain(A).






Installation

1. Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No.1 cylinder be positioned at TDC.




(1) Check the dowel pin of the crankshaft for facing upside of the engine at this moment.
(2) Install the timing chain guide(A).

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





(3) When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.
Order : Crankshaft sprocket -> Timing chain guide -> Intake camshaft sprocket -> Exhaust camshaft sprocket.
2. Install the chain tensioner arm(A).

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





3. Install the hydraulic tensioner(A) and remove the pin(B).

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






NOTE:
Recheck the top dead center(TDC) marks on the crankshaft and camshaft.

4. Install the timing chain cover(A).
(1) Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
(2) Apply the liquid gasket(TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.

Width :3 - 5mm(0.1181 - 0.1969in.)





(3) Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts of the timing chain cover and THREE BOND 1217H or LOCTITE 5900H on the rest parts. Reassemble the cover(A) within 5 minutes.

Width :3.5 - 4.5 mm (0.1378 - 0.1772 in.)


CAUTION:
Remove oil or dust on the surface surely.

(4) Align the dowel pin of the cylinder block and the holes of the oil pump.

Tightening torque :
12mm bolts :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
10mm bolts :
9.8 - 11.8 Nm (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)






CAUTION:
After the installation, do not crank engine or apply pressure on the cover for half an hour.

5. Using the SST(09455-21200), reassemble the timing chain cover oil seal(A).




6. Install the crankshaft pulley(A).

Tightening torque :
127.5 - 137.3N.m (13.0 - 14.0kgf.m, 94.0 - 101.3lb-ft)






NOTE:
When installing the pulley, remove the starter and fix the SST(09231-2B100).





NOTE:
When installing the pulley, the groove on the pulley should be positioned outside.




7. Install side cover.

Tightening torque :
8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 8.0 lb-ft)


8. Install the front right wheel and tire.
9. Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
10. After applying the liquid gasket, THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.

Width :2.0 - 2.5mm(0.0787 - 0.0984in.)





11. Install the cylinder head cover(A) with a new gasket(B).





CAUTION:
Do not reuse the disassembled gasket.

12. Tighten the cylinder head cover bolts(A) with the order and steps.

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)





13. Install the ignition coils(A).

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





14. Install the positive crankcase ventilation(PCV) hose(A) and the positive and PCSV hose(B).




15. Connect the ignition coil connector(A) and the breather hose(B).




16. Install the drive belt idler(A).

Tightening torque :
42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)





17. Install the water pump(A) with a gasket.
Tighten bolts with the order below.

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





18. Install the water pump pulley(A).

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






CAUTION:
Tighten the bolts diagonally.

19. Install the engine support bracket(A).

Tightening torque :
29.4 - 41.2 N.m (3.0 - 4.2 kgf.m, 21.7 - 30.4 lb-ft)


20. Install the alternator bracket(B).

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





21. Install the engine mounting bracket(A).

Tightening torque :
Nut(C):
63.8 - 83.4 N.m (6.5 - 8.5 kgf.m, 47.0 - 61.5 lb-ft)
Bolt(D) and Nuts(E) :
49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)





22. Install the alternator(A) and pretighten the mounting bolts.




23. Install the drive belt(A).




24. Adjust tension by tightening the alternator tension adjust bolt(A).

Tension
New belt: 882.6 - 980.7N (90 - 100kg, 198.4 - 220.5lb)
Used belt: 637.4 - 735.5N (65 - 75kg, 143.3 - 165.3lb)





25. Tighten the alternator mounting bolts.

Tightening torque :
12mm bolt :
19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)
14mm bolt :
29.4 - 41.2 N.m (3.0 - 4.2 kgf.m, 21.7 - 30.4 lb-ft)