1. |
Disconnect the battery nagative
cable. |
2. |
Remove the engine cover (A).

|
3. |
Remove the RH front
wheel. |
4. |
Remove the RH side
cover. |
5. |
Set No.1 cylinder to
TDC/compression.

|
6. |
Drain the engine oil, and then set a jack to
the oil pan.
Place wooden block between the jack and
engine oil
pan. | |
7. |
Disconnect the ground cable and then remove
the engine mounting bracket (A).

|
8. |
Remove the drive belt (A).

|
9. |
Remove the compressor lower
bolts.

|
10. |
Remove the compressor bracket
(A).

|
11. |
Remove the idler (A) and drive belt tensioner
pulley (B).

The tensioner pulley bolt has LEFT
handed
threads. | |
12. |
Remove the water pump pulley (A), crankshaft
pulley (B).

There are two methods to hold the ring
gear when installing or removing the crankshaft damper
pulley.
•
|
Install the SST (09231-2B100) to
hold the ring gear after removing the
starter.

|
•
|
Install the SST (09231-3D100) to
hold the ring gear after removing the dust
cover. |
1. |
Remove the dust cover (A) on the
bottom of the ladder frame and unfasten the two
transaxle mounting bolts (B).

|
2. |
Adjust the length of the holder
nuts (A) so that the front plate of the holder (B) puts
in the ring gear (C)
teeth. |
3. |
Adjust the angle of the links (D)
so that the two transaxle mounting bolts can be fastened
to the original mounted holes.

|
4. |
Install the SST (09231-3D100)
using the two transaxle mounting bolts and spacers.
Tighten the bolts and nuts of the holder and links
securely.

| | |
13. |
Remove the oil pan (A).

Use the SST (Oil pan remover,
09215-3C000) be careful not to damage the contact surfaces of
cylinder block and oil
pan. | |
14. |
Remove the breather hose (A).

|
15. |
Disconnect the PCV hose (A) and the exhaust
OCV connector (B). |
16. |
Disconnect the ignition coil connectors (C),
and then remove the ignition coils.

|
17. |
Remove the cylinder head cover
(A).

|
18. |
Remove the timing chain cover (A) by gently
prying between the timing chain cover and the cylinder
block.

Be careful not to damage the contact
surfaces of cylinder block, cylinder head and timing chain
cover. | |
19. |
The key of crankshaft should be aligned with
the mating face of main bearing cap. As a result of this, the piston
of No.1 cylinder is placed at the top dead center on compression
stroke.
Before removing the timing chain, mark
the timing chain with an identification based on the location
of the sprocket because the identification mark on the chain
for TDC (Top Dead Center) can be
erased. |


|
20. |
Install a set pin after compressing the timing
chain tensioner.

|
21. |
Remove the timing chain tensioner (A) and
timing chain tensioner arm (B).

|
22. |
Remove the timing
chain. |
23. |
Remove the timing chain guide
(A).

|
24. |
Remove the timing chain oil jet
(A). |
25. |
Remove the crankshaft chain sprocket
(B).

|
26. |
Remove the balance shaft chain (oil pump
chain).
(Refer to Lubrication system in this
group) |
Sprockets, Hydraulic Tensioner, Chain Guide,
Tensioner Arm
1. |
Check the CVVT sprocket, crankshaft sprocket
teeth for abnormal wear, cracks or damage. Replace if
necessary. |
2. |
Check a contact surface of the chain tensioner
arm and guide for abnormal wear, cracks or damage. Replace if
necessary. |
3. |
Check the hydraulic tensioner for its piston
stroke and ratchet operation. Replace if necessary.
|
Belt, Idler, Pulley
1. |
Check the idler for excessive oil leakage,
abnormal rotation or vibration. Replace if
necessary. |
2. |
Check belt for maintenance and abnormal wear
of V-ribbed part. Replace if
necessary. |
3. |
Check the pulleys for vibration in rotation,
oil or dust deposit of V-ribbed part. Replace if
necessary. |
1. |
Install the balance shaft chain (Oil pump
chain). (Refer to Lubrication system in this
group) |
2. |
Install the crankshaft chain sprocket
(B). |
3. |
Install the timing chain oil jet (A).
Tightening
torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~
7.2lb-ft)
|

|
4. |
Set the crankshaft so that the key (A) of
crankshaft will be aligned with the mating surface of main bearing
cap. Put the intake and exhaust camshaft assembly so that the TDC
marks (B) of the intake and exhaust CVVT sprockets will be aligned
with the top surface of cylinder head. As a result of this, the
piston of No.1 cylinder is placed at the top dead center on
compression stroke.


|
5. |
Install the timing chain guide
(A).
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

|
6. |
Install the timing chain.
To install the timing chain with no slack
between each shaft (cam, crank), follow the below
procedure.Crankshaft sprocket (A) → Timing chain guide (B) → Intake
CVVT assembly (C) → Exhaust CVVT assembly (D).
The timing mark of each sprockets should be
matched with timing mark (color link) of timing chain at installing
timing chain.



|
7. |
Install the timing chain tensioner arm
(B).
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
| |
8. |
Install the timing chain auto tensioner (A)
and remove the set pin.
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

|
9. |
After rotating crankshaft 2 revolutions in
regular direction (clockwise viewed from front), confirm the timing
mark.

|
10. |
Install timing chain cover.
A. |
Using a gasket scraper, remove all the
old gasket meterial from the gasket
surfaces. |
B. |
The sealant locations on chain cover and
on counter parts (cylinder head, cylinder block, and ladder
frame) must be free of engine oil and ETC.
|
C. |
Before assembling the timing chain
cover, the liquid sealant Loctite 5900H or THREEBOND 1217H
should be applied on the gap between cylinder head and
cylinder block.
The part must be assembled within 5
minutes after sealant was applied.
Bead
width :
3.0mm(0.12in.)
|

|
D. |
After applying liquid sealant Loctite
5900H or THREE BOND 1217H on timing chain cover. The part must
be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.
Bead
width :
3.0mm(0.12in.)
|

|
E. |
The dowel pins on the cylinder block and
holes on the timing chain cover should be used as a reference
in order to assemble the timing chain cover to be in exact
position.
Tightening torque :
6x25 : 7.8 ~ 9.8N.m (0.8 ~
1.0kgf.m, 5.8 ~ 7.2lb-ft)
8x28 : 18.6 ~ 22.5N.m (1.9 ~
2.3kgf.m, 13.7 ~ 16.6lb-ft)
10x45 : 39.2 ~ 44.1N.m (4.0 ~
4.5kgf.m, 28.9 ~ 32.5lb-ft)
10x40 : 39.2 ~ 44.1N.m (4.0 ~
4.5kgf.m, 28.9 ~ 32.5lb-ft)
|

|
F. |
Running the engine or performing a
pressure test should not be performed within 30 minutes of
assembly. | |
11. |
Install the oil pan.
A. |
Using a gasket scraper, remove all the
old packing material from the gasket surfaces.
|
B. |
Before assembling the oil pan, the
liquid sealant Loctite 5900H or THREEBOND 1217H should be
applied on oil pan. The part must be assembled within 5
minutes after the sealant was applied.
Bead
width: 3.0mm
(0.12in)
|

• |
When applying sealant
gasket, sealant must not protrud into the inside
of oil pan. |
• |
To prevent leakage of oil,
apply sealant gasket to the inner threads of the
bolt holes.
| | |
C. |
Install the oil pan (A).
Uniformly tighten the bolts in several
passes.
Tightening torque :
M9 (B) : 30.4 ~ 34.3N.m (3.1 ~
3.5kgf.m, 22.4 ~ 25.3lb-ft)
M6 (C) : 9.8 ~ 11.8N.m (1.0 ~
1.2kgf.m, 7.2 ~ 8.7lb-ft)
|

|
D. |
After assembly, wait at least 30 minutes
before filling the engine with oil.
| |
12. |
Install the cylinder head cover.
A. |
The hardened sealant located on the
upper area between timing chain cover and cylinder head should
be removed before assembling cylinder head
cover. |
B. |
After applying sealant (Loctite 5900H),
it should be assembled within 5 minutes.
Bead
width : 2.5mm(0.1in.)
|

|
C. |
Running the engine or performing a
pressure test should not be performed within 30 minutes of
assembly. |
D. |
Install the cylinder head cover bolts in
the following sequence.
Tightening torque :
Step 1 : 3.9 ~ 5.9N.m (0.4 ~
0.6kgf.m, 2.9 ~ 4.3lb-ft)
Step 2 : 7.8 ~ 9.8N.m (0.8 ~
1.0kgf.m, 5.8 ~ 7.2lb-ft)
|

Do not reuse cylinder head cover
gasket. | | |
13. |
Install the breather hose (A).

|
14. |
Connect the PCV hose (A) and exhaust OCV
connector (B). |
15. |
Install the ignition coils and then connect
the ignition coil connectors (C).

|
16. |
Install the crankshaft pulley
(B).
Tightening
torque :
166.6 ~ 176.4N.m (17.0 ~ 18.0kgf.m,
122.9 ~ 130.1lb-ft)
|
There are two methods to hold the ring
gear when installing or removing the crankshaft damper
pulley.
•
|
Install the SST (09231-2B100) to
hold the ring gear after removing the
starter.

|
•
|
Install the SST (09231-3D100) to
hold the ring gear after removing the dust
cover. |
1. |
Remove the dust cover (A) on the
bottom of the ladder frame and unfasten the two
transaxle mounting bolts (B).

|
2. |
Adjust the length of the holder
nuts (A) so that the front plate of the holder (B) puts
in the ring gear (C)
teeth. |
3. |
Adjust the angle of the links (D)
so that the two transaxle mounting bolts can be fastened
to the original mounted holes.

|
4. |
Install the SST (09231-3D100)
using the two transaxle mounting bolts and spacers.
Tighten the bolts and nuts of the holder and links
securely.

| | |
17. |
Install the water pump pulley
(A).
Tightening
torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~
7.2lb-ft)
|

|
18. |
Install the drive belt tensioner pulley
(B).
Tightening
torque :
53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~
47.0lb-ft)
|
The tensioner pulley bolt has LEFT
handed
threads. | |
19. |
Install the idler (A).
Tightening
torque :
53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~
47.0lb-ft)
|

|
20. |
Install the air compressor bracket
(A).
Tightening
torque :
19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m,13.7 ~
14.5lb-ft)
|

|
21. |
Install the air compressor lower
bolts.
Tightening
torque :
20.0 ~ 32.9N.m (2.04 ~ 3.36kgf.m, 14.8 ~
24.3lb-ft)
|

|
22. |
Install the drive belt (A).
Crankshaft pulley -> A/C pulley ->
Alternator pulley -> Idler pulley -> Idler pulley -> Water
pump pulley -> Tensioner pulley.
Rotate the auto tensioner counter - clockwise.
With the tensioner turned, install the drive belt on auto tensioner
and then release the tensioner.

|
23. |
Install the engine mounting bracket (A) and
then connect the ground cable.
Tightening
torque :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9
~ 72.3 lb-ft)
|

|
24. |
Install the RH side cover.
Tightening
torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~
7.9lb-ft)
| |
25. |
Install the RH front wheel.
Tightening
torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~
79.6lb-ft)
| |
26. |
Install the engine cover
(B). |
27. |
Reconnect the battery nagative cable
(A).
Tightening
torque:
(-) terminal : 4.0 ~ 6.0N.m (0.4 ~
0.6kgf.m, 3.0 ~ 4.4lb-ft)
|

•
|
Clean the battery posts and cable
terminals with sandpaper. Assemble and then apply grease
to prevent corrosion. |
•
|
Inspect for fuel leakage.
|
-
|
After assembling the fuel line,
turn on the ignition switch (do not operate the starter)
so that the fuel pump runs for approximately two seconds
and fuel line pressurizes.
|
-
|
Repeat this operation two or three
times, then check for fuel leakage at any point in the
fuel lines. |
•
|
Refill radiator and reservoir tank
with engine coolant. |
•
|
Bleed air from the cooling
system. |
-
|
Start engine and let it run until
it warms up. (Until the radiator fan operates 3 or 4
times.) |
-
|
Turn Off the engine and let it
cool down. Check the level in the radiator, add coolant
if needed. This will allow trapped air to be removed
from the cooling
system. |
-
|
Put radiator cap on tightly, then
run the engine again and check for
leaks. | | | |