Repair Procedures

Removal

1. Remove the engine cover (A).




2. Remove the RH front wheel.
3. Remove the RH side cover.
4. Set No.1 cylinder to TDC/compression.




5. Drain the engine oil, and then set a jack to the oil pan.

NOTE:
Place wooden block between the jack and engine oil pan.

6. Disconnect the ground line (A) and remove the engine mounting bracket (B).




7. Remove the drive belt (A).




8. Remove the idler (A) and drive belt tensioner (B).





CAUTION:
Tensioner pulley bolt is left - handed screw.

9. 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.





10. Disconnect the exhaust OCV connector (A) and remove the wiring from the cylinder head cover.




11. Remove the breather hose (A).




12. Remove the PCV hose (A).




13. Disconnect the ignition coil connectors (A).




14. Remove the ignition coils (A).




15. Remove the cylinder head cover (A).




16. Remove the compressor lower bolts.




17. Remove the compressor bracket (A).




18. Using the SST(09215-3C000), remove the oil pan(A).





CAUTION:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of 1 arrow.
- After tapping the SST with a plastic hammer along the direction of 2 arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It can result in damage of the SST.

19. Remove the timing chain cover (A) by prying the portions between the cylinder head and cylinder block with a screwdriver.





CAUTION:
Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

20. 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.
21. Install a set pin after compressing the timing chain tensioner.




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




23. Remove the timing chain.
24. Remove the timing chain guide (A).




25. Remove the timing chain oil jet (A).
26. Remove the crankshaft chain sprocket (B).




27. Remove the balance shaft chain.


Inspection

Sprockets, Hydraulic Tensioner, Chain Guide, Tensioner Arm
1. Check the CVVT sprocket, crankshaft sprocket teeth for abnormal wear, cracks or damage. Replace if necessary.
2. Check a contact surface of the chain tensioner arm and guide for abnormal wear, cracks or damage. Replace if necessary.
3. Check the hydraulic tensioner for its piston stroke and ratchet operation. Replace if necessary.

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 crankshaft chain sprocket (B).
2. Install the timing chain oil jet (A).

Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




3. 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.








4. Install the timing chain guide (A).

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




5. 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 camshaft sprocket (C) -> Exhaust camshaft sprocket (D).
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.




6. Install the timing chain tensioner arm (B).

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

7. Install the timing chain auto tensioner (A) and remove the set pin.

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




8. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.




9. Install timing chain cover.
A. 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.
B. Before assembling the timing chain cover, the liquid sealant Loctite 5900H 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.)




C. 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.)




D. 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 : 7.8 - 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)




E. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
10. Install the oil pan.
A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
B. 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.





CAUTION:
- When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
- To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

C. Install the oil pan (A).
Uniformly tighten the bolts in several passes.

Tightening torque :
M8 (B) : 26.5 - 30.4N.m ( 2.7 - 3.1kgf.m, 19.5 - 22.4lb-ft)
M6 (C) : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




D. After assembly, wait at least 30 minutes before filling the engine with oil.
11. Install the air compressor bracket (A).

Tightening torque :
19.6 - 23.5N.m (2.0 - 2.4kgf.m,13.7 - 14.5lb-ft)




12. Install the air compressor lower bolts.

Tightening torque :
19.6 - 24.5N.m (2.0 - 2.5kgf.m,13.7 - 18.1lb-ft)




13. Install the cylinder head cover.
A. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
B. After applying sealant (Loctite 5900H), it should be assembled within 5 minutes.

Bead width :2.5mm(0.1in.)




C. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
D. Install the cylinder head cover bolts as following method.

Tightening torque :
Step 1 : 3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2 : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)





CAUTION:
Do not reuse cylinder head cover gasket.

14. Install the ignition coils (A).

Tightening torque :
3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)




15. Connect the ignition coil connectors (A).




16. Install the PCV hose (A).




17. Install the breather hose (A).




18. Connect the exhaust OCV connector (A) and replace the wiring on the cylinder head cover.




19. 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)

20. 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.





21. Install the water pump pulley (A).

Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




22. Install the drive belt tensioner (B).

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.

23. Install the idler (A).

Tightening torque :
53.9 - 63.7N.m (5.5 - 6.5kgf.m, 39.7 - 47.0lb-ft)




24. 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.




25. Install the engine mounting bracket (B) and ground line (A).

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




26. Install the RH side cover.

Tightening torque :
8.8 - 10.8N.m (0.9 - 1.1kgf.m, 6.5 - 7.9lb-ft)

27. Install the RH front wheel.

Tightening torque :
88.3 - 107.9N.m (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)

28. Install the engine cover (A).