Repair Procedures
Removal
1. Disconnect the battery negative cable (A).
2. Remove the engine cover (B).
3. Remove RH front wheel.
4. Remove RH side cover.
5. Set No.1 cylinder to TDC/compression.
6. Drain the engine oil, and then set a jack to the oil pan.
NOTE:
Place wooden block between the jack and engine oil pan.
7. Disconnect the ground line and then remove the engine mounting bracket (A).
8. Remove the drive belt (A).
9. Remove the idler (A) and drive belt tensioner (B).
CAUTION:
Tensioner pulley bolt is left - handed screw.
10. 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.
11. Disconnect the ignition coil connectors (A) and remove the ignition coils.
12. Remove the cylinder head cover (A).
13. Remove the compressor lower bolts.
14. Remove the compressor bracket.
15. Remove the oil pan.
CAUTION:
Be careful not to damage the contact surfaces of cylinder block and oil pan.
16. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block.
CAUTION:
Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
17. 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.
18. Install a set pin after compressing the timing chain tensioner.
19. Remove the timing chain tensioner (A) and timing chain tensioner arm (B).
[Single CVVT]
[Dual CVVT]
20. Remove the timing chain.
21. Remove the timing chain guide (A).
[Single CVVT]
[Dual CVVT]
22. Remove the timing chain oil jet (A).
23. Remove the crankshaft chain sprocket (B).
24. Remove the oil pump chain.
Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the camshaft 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 oil pump chain.
2. Install the crankshaft 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)
[Single CVVT]
[Dual CVVT]
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 or camshaft sprocket (D).
[Single CVVT]
[Dual CVVT]
NOTE:
The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.
[Single CVVT]
[Dual CVVT]
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)
[Single CVVT]
[Dual CVVT]
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, remove all the old packing 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 THREEBOND 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 :2.5mm (0.1in.)
(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 :2.5mm (0.1in.)
(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:
The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
11. Install 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
CAUTION:
- When applying sealant gasket, sealant must not be protruded into the inside of 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
M8 bolts : 26.5 - 30.4N.m (2.7 - 3.1kgf.m, 19.5 - 22.4lb-ft)
M6 bolts : 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.
12. Install the air compressor bracket.
Tightening torque :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 13.7 - 14.5lb-ft)
13. Install the compressor lower bolts.
Tightening torque :
19.6 - 24.5N.m (2.0 - 2.5kgf.m, 13.7 - 18.1lb-ft)
14. 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 as following method.
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.
15. Install the ignition coils and connect the ignition coil connectors (A).
16. 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)
17. 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.
18. Install the water pump pulley (A).
Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
19. 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)
NOTE:
Tensioner pulley bolt is left-handed screw.
20. Install idler pulley (A).
Tightening torque :
53.9 - 63.7N.m (5.5 - 6.5kgf.m, 39.7 - 47.0lb-ft)
21. 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 auto tensioner arm in the counter - clockwise moving auto tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.
22. Install the engine mounting bracket (A) and then connect the ground cable.
Tightening torque :
63.7 - 83.4N.m (6.5 - 8.5kgf.m, 47.0 - 61.5lb-ft)
23. Remove the RH side cover.
Tightening torque :
8.8 - 10.8N.m (0.9 - 1.1kgf.m, 6.5 - 7.9lb-ft)
24. Install the RH front wheel.
Tightening torque :
88.3 - 107.9N.m (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)
25. Install the engine cover (B).
26. Connect the battery negative cable (A).