1. |
Remove the alternator
belt. |
2. |
Remove the coolant pump
pulley. |
3. |
Remove the power steering belt and
airconditioner belt. |
4. |
Remove the crankshaft pulley.

|
5. |
Remove the timing belt cover.


|
6. |
Remove the timing belt tensioner
pulley.

If the timing belt is reused, make an
arrow indicating the turning direction (or the front of the
engine) to make sure that the belt is reinstalled in the same
direction as
before. | |
7. |
Remove the timing belt.

|
8. |
Remove the idler pulley.

|
9. |
Remove the cylinder headcover.

|
10. |
Remove the camshaft sprocket.

Be careful not to damage the cylinder
head with the
wrench. | |
11. |
Remove the crankshaft sprocket from
crankshaft.

|
SPROCKETS,
1. |
Check the camshaft sproket, crankshaft
sprocket, tensioner pulley, and idler pulley for abnormal wear,
cracks, or damage. Replace as
necessary. |
2. |
Inspect the tensioner pulley and the idler
pulley for easy and smooth rotation and check for play or noise.
Replace as necessary. |
3. |
Replace the pulley if there is a grease leak
from its bearing.

|
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.
•
|
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.

| |
Description
|
Flaw
conditions
|
1. Hard
back surface of rubber
|
Back
surface is glossy, non-elastic and so hard that, when your
fingernail is pressed into it, no mark is produced.

|
2. Cracked
back surface of rubber
|

|
3. Cracked
or separating canvas
|



|
4. Badly
worn teeth (initial stage)
|
Tooth
flank shows canvas on the load side (Fluffy canvas fibers,
rubber changed into white color and unclear canvas
texture)

|
5. Badly
worn teeth (last stage)
|
Tooth
flank worn and rubber exposed on load side (tooth width reduced)

|
6. Cracked
tooth bottom
|

|
7. Missing
tooth
|

|
8. Badly
worn side of belt
Normal belt should have precisely
cut side as if cut by a sharp
knife. | |

|
9. Cracked
side of belt
|

|
|
1. |
Install the camshaft sprocket and tighten the
bolt to the specified torque
(1) |
Temporarily install the camshaft
sprocket bolt. |
(2) |
Hold the hexagonal head wrench portion
of the camshaft with a wrench, and tighten the camshaft
sprocket bolt.
Tightening torque
Camshaft sprocket
bolt
100 ~ 120Nm (1000 ~ 1200kgf.cm, 74
~ 89lbf.ft)
|

| |
2. |
Install cylinder head cover.
(1) |
Install cylinder head cover and
12bolts.

|
(2) |
Install the PCV hose and breather
hose.

|
(3) |
Install the accelerator cable from the
cylinder head cover.

|
(4) |
Install the spark plug
cable. | |
3. |
Install the crankshaft sprocket.

|
4. |
Align the timing marks of the camshaft
sprocket and crankshaft sprocket with the No. 1 piston placed at top
dead center and its compression stroke.


|
5. |
Install the idler pulley and tighten the bolt
to the specified torque.
Tightening
torque
Idler pulley bolt :
43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~
40lbf.ft)
|

|
6. |
Temporarily install the timing belt tensioner
with plain washer.

|
7. |
Belt so as not give slack at each center of
shaft. Do as following procedures when installing timing
belt.
Crankshaft sprocket(A) → Idler pulley(B) →
Camshaft sprocket(C) → Timing belt tensioner(D).

|
8. |
Temporarily fasten tensioner pulley by center
bolt to add force at belt. |
9. |
Timing belt tension adjusting.
(1) |
Rotate crankshaft in regular direction
(clock wise view from front) through angle equivalant to two
teeth (18°) of camshaft sprocket.

|
(2) |
Give tension to timing belt by rotating
tensioner in arrow driection with tool and set timing belt not
to give slack to tension side |
(3) |
Tightening tensioner bolt.
Tightening torque
Tensioner bolt :
43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~
40lbf.ft)
| |
(4) |
Recheck the belt tension. When the
tension side of timing belt is pushed horizontally with a
moderate force [approx. 2kg (20N, 5lb)], the timing belt cog
end sags in approx. 4 ~ 6mm (0.16 ~ 0.24in.).

| |
10. |
Turn the crankshaft two turns in the operating
direction (clockwise) and realign crankshaft sprocket and camshaft
sprocket timing mark. |
11. |
Install the timing belt lower cover with 5
bolts.
Tightening
torque
Timing belt cover bolt :
8 ~ 10Nm (80 ~100kg.cm, 6 ~
7lbf.ft)
|

|
12. |
Install the flange and crankshaft
pulley.
Make sure that crankshaft sprocket pin fits
the small hole in the pulley.
Tightening
torque
Crankshaft pulley bolt :
170 ~ 180Nm (1700 ~ 1800kgf.cm, 125 ~
133lbf.ft)
|

|
13. |
Install the timing belt upper cover with
4bolts.

|
14. |
Install the coolant pump pulley with
4bolts. |
15. |
Install power steering
belt. |
16. |
Install air compressor
belt. |
17. |
Install alternator
belt |
18. |
Install the engine mount bracket.
(1) |
Install the stay plate with
bolt.
Tightening torque
Stay plate bolt :
43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~
40lbf.ft)
|

|
(2) |
Install engine mount bracket with 3nuts
and bolt.
Tightening torque
17mm nut : 60 ~80Nm (600 ~
800kgf.cm, 44 ~ 59lbf.ft)
14mm nut : 50 ~65Nm (500 ~
650kgf.cm, 37 ~ 48lbf.ft)
|

| |
19. |
Install RH side cover with
2bolts.

|
20. |
Install RH front
wheel. |
21. |
Install engine cover with 5bolts.

| |