Repair Procedures

REMOVAL

1. Remove the engine cover.
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) and the ground cable(B).

8. Remove the crankshaft damper pulley(A).

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

10. Remove the engine support bracket(A).

NOTE:
After the removal, engine coolant can be drained a little from that point(B) which is a matter of no importance.

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

12. Remove the timing belt(A).

NOTE:
Make a direction mark of revolution on the timing belt for reseal.

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

14. Remove the crankshaft sprocket.

REMOVAL

1. Remove the engine cover.
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).

8. Remove the crankshaft damper pulley(A).

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

10. Remove the engine support bracket(A).

NOTE:
After the removal, engine coolant can be drained a little from that point(B) which is a matter of no importance.

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

12. Remove the timing belt(A).

NOTE:
Make a direction mark of revolution on the timing belt for reseal.

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. Install the timing belt auto tensioner.
(1) Fixing the tensioner with a vise and compressing the rod, insert a set-pin.

NOTE:
- Handle the auto tensioner in the vertical position.
- If it is treated by laying, tilting or turning over, stand it vertically for about five minutes in order for air to move upward.
- Do not pull the pin out before its installation to the engine assembly because pulling the pin can cause noise of timing system by making air go in the high pressure chamber.

CAUTION:
- When pressing the rod, use a vertical vise.
- There is a high possibility for air to get in the high pressure chamber, when using a horizontal vise.
- Do not apply more load than 400N on the rod.
- Do not press the rod until its position is below 2.5mm from the body surface.
- The projection of the rod is secured more than 2.5mm.

NOTE:
- Before installing the tensioner :
1. Place the tensioner in a vertical position for 5 minutes.
2. Press the rod with a force of about 150-200N (34-45LB).
3. If resistance is felt, fully compress the rod and insert the set pin.
4. If resistance is insufficient, slowly compress the rod from the fully extended position to the point where the rod extends about 2.9mm from the surface of the tensioner.
Repeat this process 3 times, then repeat step 2 and re-check.
If resistance is still not sufficient, replace the tensioner.

(2) 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)

4. Verify the alignment of the timing marks on the camshaft and the crankshaft sprockets.

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

6. Remove the auto tensioner set-pin.
7. Check the tension of the timing belt.
(1) Turn the crankshaft 2 rev. clockwise which makes the No.1 cylinder piston position at 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:
- Over torque can damage thread of cylinder block.
- Be care the difference of upper 2 bolts and lower 1 bolt length.

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

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

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) and the ground cable(B).

Tightening torque
(A) : 63.7 - 83.4Nm(6.5 - 8.5kgf.m, 47.0 - 61.5lb-ft)
(B) : 7.8 - 11.8Nm(0.8 - 1.2kgf.m, 5.8 - 8.7lb-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.

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. Install the timing belt auto tensioner.
(1) Fixing the tensioner with a vise and compressing the rod, insert a set-pin.

4. Verify the alignment of the timing marks on the camshaft and the crankshaft sprockets.

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

(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)

10. Install the crankshaft damper pulley(A).

Tightening torque
230.5 - 240.3N.m (23.5 - 24.5kgf.m, 170.0 - 177.2lb-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)

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

INSPECTION

SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket and crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner and the idler for easy and smooth rotation and check for play or noise. Replace as necessary.

3. Replace the tensioner and the idler if grease is leaked from bearings.

TIMING BELT
1. Check the belt for oil or dust deposits.
Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following flaws are evident, replace the belt.

NOTE:
- Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water and steam.

3. Inspect the idler for easy and smooth rotation and check for play or noise.