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. |
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. (Refer to Alternatorin
EE Group) |
7. |
Remove air compressor belt. (Refer to Air
compressor in HA Group) |
8. |
Remove power steering belt. (Refer to Power
steering pump in ST Group) |
9. |
Remove 4bolts and water pump
pulley. |
10. |
Remove the 4bolts and timing belt upper
cover. |
11. |
Turn the crankshaft pulley, and align its
groove with timing mark "T" of the timing belt
cover. |
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. |
(3) |
Remove the PCV(Positive Crankcase
ventilation) hose and breather
hose. |
(4) |
Remove the 12bolts and cylinder head
cover. | |
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
98.1 ~ 117.7Nm (10.0 ~ 12.0kgf.m,
72.3 ~ 86.8lb-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
42.2 ~ 53.9Nm (4.3 ~ 5.5kgf.m, 31.1 ~
39.8lb-ft)
|

|
6. |
Install the timing belt tensioner loosely
enough for the adjuster to rotate. Make sure that the stopper of
base is leaning against the lowering sealing cap on the cylinder
head. |
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).
(The tensioner can be installed after the
timing belt.)

|
8. |
Check the alignment of the timing marks on
each sprocket. |
9. |
Remove the pin fixing the tensioner
arm. |
10. |
Using a hex wrench, turn the adjuster
counterclockwise to make the indicator of the arm (A) located at the
center of the base notch.

Do not rotate the adjuster
clockwise.
It will result in auto tensioner's
functional
problem. | |
11. |
Tightening tensioner bolt with fixing the
indicator not to move.
Tightening
torque
Tensioner bolt :
22.6 ~ 28.4Nm (2.3 ~ 2.9kgf.m, 16.6 ~
21.0lb-ft)
| |
12. |
Turn the crankshaft two revolutions in the
operating direction (clockwise) and check that the indicator is in
the center of base. |
13. |
If the indicator is not located at the center
of base, slacken the bolt and repeat the abore
procedure. |
14. |
Install the timing belt lower cover(A) with 5
bolts(B).
Tightening
torque
Timing belt cover bolt
7.8 ~ 9.8Nm (0.8 ~1.0kgf.m, 5.8 ~
7.2lb-ft)
|

|
15. |
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
156.9 ~ 176.5Nm (16.0 ~ 17.0kgf.m, 115.7
~ 130.2lb-ft)
|

|
16. |
Install the timing belt upper cover with
4bolts. |
17. |
Install the coolant pump pulley with
4bolts. |
18. |
Install power steering belt. (Refer to Power
steering pump in ST Group) |
19. |
Install air compressor belt. (Refer to Air
compressor in HA Group) |
20. |
Install alternator belt. (Refer to Alternator
in EE Group) |
21. |
Install the engine mount bracket.
(1) |
Install the stay plate(A) with
bolt(B).
Tightening torque
Stay plate bolt
42.2 ~ 53.9Nm (4.3 ~ 5.5kgf.m 31.1
~ 39.8lb-ft)
|

|
(2) |
Install engine mount bracket(A) with
3nuts and bolt.
Tightening torque
Bolt(B), Nuts(C)
49.0 ~ 58.8Nm (5.0 ~ 6.0kgf.m,
36.2 ~ 43.4lb-ft)
Nut(D) : 58.8 ~ 78.5Nm (6.0 ~
8.0kgf.m 43.4 ~ 57.9lb-ft)
|

| |
22. |
Install RH side cover(A) with
2bolts(B).

|
23. |
Install RH front
wheel. |
24. |
Install engine cover with
4bolts. |
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. | | |