Engine removal is not
required for this procedure.
1. |
Remove the engine
cover. |
2. |
Remove RH front
wheel. |
3. |
Remove 2bolts(B) and RH side
cover(A).

|
4. |
Turn the crankshaft pulley, and align its
groove with timing mark "T"of the timing belt cover.

Always turn the crankshaft
clockwise. | |
5. |
Remove drive belt(A) and belt
tensioner(B).

|
6. |
Remove the engine mount bracket.
(1) |
Set the jack to the engine oil
pan.

Place wooden block between the
jack and engine oil
pan. | |
(2) |
Remove the 2bolts, 2nuts and engine
mount bracket(A).

| |
7. |
Remove the power steering pump. (See ST group
- power steering pump) |
8. |
Remove the 7bolts(B) and timing belt upper
cover(A).

|
9. |
Remove the crankshaft pulley bolt and
crankshaft pulley(A).

|
10. |
Remove the drive belt idler
pulley(A).

|
11. |
Remove the 4bolts(B) and timing belt lower
cover(A).

|
12. |
Remove the engine support
bracket(A).

|
13. |
Check that timing marks of the camshaft timing
pulleys and cylinder head covers are aligned.
If not, turn the crankshaft
1revolution(360°). |
14. |
Remove timing belt tensioner.
Alternately loosen the 2bolts, and remove the
tensioner(A).

|
15. |
Remove the timing belt(A).

If the timing belt is reused, make an
arrow indicating the turning direction to make sure that the
belt is reinstalled in the same direction as
before. | |
16. |
Remove the tensioner pulley(A) and timing belt
idler pulley(B).

|
17. |
Remove the crankshaft
sprocket. |
18. |
Remove camshaft sprockets.
Hold the hexagonal head wrench portion of the
camshaft with a wrench and remove the bolt and camshaft
sprocket.
Be careful not to damage the cylinder
head and valve lifter with the
wrench. | |
1. |
Install the crankshaft sprocket.
Align the pulley set key with the key groove
the crankshaft sprocket and slide on the crankshaft
sprocket. |
2. |
Install the camshaft sprockets and tighten the
bolts to the specified torque.
(1) |
Temporarily install the camshaft
sprocket bolts. |
(2) |
Hold the hexagonal head wrench portion
of the camshaft with a wrench, and tighten the camshaft
sprocket bolts.
Tightening torque
Camshaft sprocket
bolt
90 ~ 110Nm (900 ~ 1100kgf.cm, 65 ~
80lbf.ft)
| | |
3. |
Install the idler pulley(B) and the tensioner
pulley(A).
Tightening
torque
Idler pulley bolt
50 ~ 60Nm (500 ~ 600kgf.cm, 36 ~
43lbf.ft)
Tensioner arm fixed bolt
35 ~ 55Nm (350 ~ 550kgf.cm, 25 ~
40lbf.ft)
|
Insert and install the idler pulley to
the roll pin that is pressed in the water pump
boss. |

|
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. |
Set timing belt tensioner.
(1) |
Using a press, slowly press in the push
rod. |
(2) |
Align the holes of the push rod and
housing pass a set pin through the holes to keep the setting
position of the push rod. |
|
6. |
Install the timing belt
tensioner.
(1) |
Temporarily install the tensioner with
the 2bolts. |
(2) |
Alternately tighten the
2bolts.
Tightening torque
20 ~ 27Nm (200 ~ 270kgf.cm, 14 ~
20lbf.ft)
|

| |
7. |
Install the timing belt.
(1) |
Remove any oil or water on the
sprockets, and keep them
clean. |
(2) |
Install the tming belt in this
order.
Crankshaft sprocket(A) → Idler pulley(B)
→ Camshaft sprocket LH side(C) → Water pump pulley(D) →
Camshaft sprocket RH side(E) → Tensioner
pulley(F).

| |
8. |
Remove the set pin(A) from the
tensioner.

|
9. |
Timing belt tensioner checking.
(1) |
Rotate the crankshaft 2turns clockwise
and measure the projected length of the auto tensioner at
TDC(#1 compression stroke) after 5
minutes. |
(2) |
The projected length should be 7 ~ 9mm
(0.27 ~ 0.31in.)

| |
10. |
Install the engine support
bracket(A).
Tightening
torque
B : 60 ~ 70Nm (600 ~ 700kgf.cm, 43 ~
51lbf.ft)
C : 15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~
16lbf.ft)
|

|
11. |
Install the timing belt lower cover(A) with
4bolts(B).
Tightening
torque
Timing belt cover bolt
10 ~ 12Nm (100 ~120kgf.cm, 7 ~
9lbf.ft)
|

|
12. |
Install the drive belt idler
pulley(A).
Tightening
torque
Idler pulley bolt
35 ~ 55Nm (350 ~ 550kgf.cm, 25 ~
40lgf.ft)
|

|
13. |
Install the crankshaft pulley(A).
Make sure that crankshaft sprocket pin fits
the small hole in the pulley.
Tightening
torque
Crankshaft pulley bolt
180 ~ 190Nm (1800 ~ 1900kgf.cm, 130 ~
138lbf.ft)
|

|
14. |
Install the timing belt upper cover(A) with
7bolts(B).

|
15. |
Install the power steering pump. (See ST group
- power steering pump) |
16. |
Install the drive belt tensioner(B) and drive
belt(A).

|
17. |
Install the engine mount bracket.
Install engine mount bracket with 2nuts and
2bolt.
Tightening
torque
60 ~ 80Nm (600 ~ 800kgf.cm, 44 ~
59lbf.ft)
|

|
18. |
Install RH side cover(A) with
2bolts(B).

|
19. |
Install RH front
wheel. |
20. |
Install engine
cover. |
SPOCKETS, TENSIONER, IDLER
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. | | |