Engine removal is not
required for this procedure.
1. |
Remove the engine cover. (See page EM -
8) |
2. |
Remove RH front
wheel. |
3. |
Remove 2bolts(B) and RH side
cover(A).

|
4. |
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 bolt(B), 3nuts(C, D) and
engine mount bracket(A).

|
(3) |
Remove the bolt(B) and stay
plate(A).

| |
5. |
Temporarily loosen the water pump pulley
bolts.

|
6. |
Remove alternator belt. (See EE group -
alternator) |
7. |
Remove air compressor belt. (See HA group -
air compressor) |
8. |
Remove power steering belt. (See ST group -
power steering pump) |
9. |
Remove 4bolts and water pump
pulley. |
10. |
Remove the 4bolts and timing belt upper cover.
(See page EM - 9) |
11. |
Turn the crankshaft pulley, and align its
groove with timing mark "T" of the timing belt cover. (See page EM -
9) |
12. |
Remove the crankshaft pulley bolt(B) and
crankshaft pulley(A).

|
13. |
Remove the crankshaft flange(A).

|
14. |
Remove the 5bolts(B) and timing belt lower
cover(A).

|
15. |
Remove the timing belt tensioner(A) and timing
belt(B).


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 bolt(B) and timing belt
idler(A).

|
17. |
Remove the crankshaft
sprocket(A).

|
18. |
Remove the cylinder head cover.
(1) |
Remove the spark plug
cable. |
(2) |
Remove the accelerator cable from the
cylinder head cover. (See page EM -
11) |
(3) |
Remove the PCV(Positive Crankcase
ventilation) hose and breather hose. (See page EM -
11) |
(4) |
Remove the 12bolts and cylinder head
cover. (See page EM -
11) | |
19. |
Remove camshaft sprocket.
(1) |
Hold the hexagonal head wrench(A)
portion of the camshaft with a wrench(B), and remove the bolt
and camshaft sprocket(C).

Be careful not to damage the
cylinder head and valve lifter with the
wrench. | | |
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(A)
portion of the camshaft with a wrench(B), and tighten the
camshaft sprocket(C) bolt.
Tightening torque
Camshaft sprocket
bolt
100 ~ 120Nm (1000 ~ 1200kgf.cm, 74
~ 89lbf.ft)
|

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

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

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

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

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


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

|
6. |
Temporarily install the timing belt
tensioner(A) with plain washer(B).

|
7. |
Install the timing belt so as not to give
excessive slack at the center of the belt. Install the timing belt
with the following procedure.
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(A).

|
(2) |
Give tension to timing belt by rotating
tensioner in direction of the arrow with tool and set timing
belt not to give slack to tension side.

|
(3) |
Tightening tensioner bolt.
Tightening torque
Tensioner bolt
22.6 ~ 28.4Nm (230 ~ 290kgf.cm,
16.6 ~ 21.0lbf.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(A) with 5
bolts(B).
Tightening
torque
Timing belt cover bolt
8 ~ 10Nm (80 ~100kg.cm, 6 ~
7lbf.ft)
|

|
12. |
Install the flange and crankshaft
pulley(A).
Make sure that crankshaft sprocket pin fits
the small hole in the pulley.
Tightening
torque
Crankshaft pulley bolt
160 ~ 170Nm (1600 ~ 1700kgf.cm, 120 ~
125lbf.ft)
|

|
13. |
Install the timing belt upper cover with
4bolts. (See page EM - 10) |
14. |
Install the coolant pump pulley with
4bolts. |
15. |
Install power steering belt. (See ST group -
power steering pump) |
16. |
Install air compressor belt. (See HA group -
air comperssor) |
17. |
Install alternator belt. (See EE group-
alternator) |
18. |
Install the engine mount bracket.
(1) |
Install the stay plate(A) with
bolt(B).
Tightening torque
Stay plate bolt
43 ~ 55Nm (430 ~ 550kgf.cm 32 ~
40lbf.ft)
|

|
(2) |
Install engine mount bracket(A) with
3nuts and bolt.
Tightening torque
Bolt(B), Nuts(C)
50 ~ 60Nm (500 ~ 600kgf.ft, 37 ~
48lbf.ft)
Nut(D) : 60 ~ 80Nm (600 ~ 800kgf.m
44 ~ 59lbf.ft)
|

| |
19. |
Install RH side cover(A) with
2bolts(B).

|
20. |
Install RH front
wheel. |
21. |
Install engine cover with 4bolts. (See page EM
- 10) |
SPOCKETS, TENSIONER, IDLER
1. |
Check the camshaft sprocket, 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. | | |