Overhaul

TIMING SYSTEM

COMPONENTS:

REMOVAL

1. Remove the engine cover.
2. Remove the front right wheel and tire.
3. Remove the right side cover.
4. Remove the drive belt(A), the idler(B) and the tensioner(C).





NOTE: In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise.

5. Remove the timing belt upper cover(A).





6. Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover at the moment.
(No.1 cylinder piston at TDC)





7. Remove the engine mounting bracket.
1) Sustain the engine oil pan with a jack.

CAUTION: Put a wooden or rubber block between the jack and the engine oil pan.

2) Remove the engine mounting bracket(A).





8. Remove the crankshaft damper pulley(A).





9. Remove the timing belt lower cover(A).





10. Remove the engine support bracket(A).





NOTE: After the removal, engine coolant can be drained a little from that point(B) which is a matter of no importance.

11. Remove the timing belt auto tensioner(A).





12. Remove the timing belt(A).

NOTE: Make a direction mark of revolution on the timing belt for reuse.





13. Remove the tensioner arm assembly(A) and the idler(B).





14. Remove the crankshaft sprocket.

INSPECTION

SPROCKETS, TENSIONER, IDLER

1. Check the camshaft sprocket and crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner and the idler for easy and smooth rotation and check for play or noise. Replace as necessary.





3. Replace the tensioner and the idler if grease is leaked from bearings.

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.

NOTE:
^ 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.

3. Inspect the idler for easy and smooth rotation and check for play or noise.

INSTALLATION

1. Install the crankshaft sprocket.
2. Install the tensioner arm assembly(A) and the idler(B).





3. Install the timing belt auto tensioner.
1) Fixing the tensioner with a vice and compressing the rod, insert a set-pin.





NOTE:
^ Handle the auto tensioner in the vertical position.
^ If it is treated by laying, tilting or turning over, stand it vertically for about five minutes in order for air to move upward.
^ Do not pull the pin out before its installation to the engine assembly because pulling the pin can cause noise of timing system by making air go in the high pressure chamber

CAUTION:
^ When pressing the rod, use a vertical vice certainly.
^ There is a high possibility for air to get in the high pressure chamber, when using a horizontal vice.
^ Do not apply more load than 400N on the rod.
^ Do not press the rod until its position is below 2.5mm from the body surface.
^ The projection of the rod is secured more than 2.5mm.

NOTE:
^ Repairing orders when disassembling the auto tensioner and reassembling it to the engine, or pulling the pin out before its installation;
1) Stand it vertically for about five minutes.
2) Press the rod with the force, 150-200N.
3) If the rod has a stiffness, press it slowly and insert the pin into the set hole.
4) If not (the tensioner is in 'sponge' state), press the rod slowly from its maximum projection to 2.9mm position(the meeting point with the rod and the hole of the body) two or three times,
Afterwards, if stiffness is sensed, insert the pin into the hole. However, if not, scrap the tensioner.

2) Install the auto tensioner(A) to the front case with the set-pin inserted.





4. Ensure the timing marks on the camshaft and the crankshaft sprockets.





5. Install the timing belt.
Crankshaft sprocket(A)->Idler(B)->Bank 2 exhaust camsprocket(C)->Water pump pulley(D)->Bank 1 exhaust camsprocket(E)->Tensioner pulley(F).





6. Remove the auto tensioner set-pin.
7. Check the tension of the timing belt.
1) Turn the crankshaft 2 rev. clockwise which makes the No.1 cylinder piston position at TDC. After 5 minutes, measure the length of the projected rod.





2) Ensure the locations of the timing marks for each sprocket.
8. Install the engine support bracket(A).





CAUTION: Over torque can damage thread of cylinder block.

9. Install the timing belt lower cover.





10. Install the crankshaft damper pulley(A).





11. Install the engine mounting bracket(A).





12. Install the timing belt upper cover(A).





13. Install the drive belt tensioner(C).

Tightening torque 34.3-53.9Nm (3.5-5.5kgf.m, 25.3-39.8 lb-ft)

14. Install the drive belt idler and the drive belt(A).





15. Install the right side cover.
16. Install the front right wheel and tire.
17. Install the engine cover.