Crankshaft Gear/Sprocket: Service and Repair

REMOVAL






1. Remove the crankshaft pulley, coolant pump pulley and drive belt.






2. Remove the timing belt cover.






3. Remove the timing belt tensioner pulley.






4. Remove the timing belt.

NOTE: If the timing belt is reused, make an arrow indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before.

5. Remove the idler pulley.






6. Using a suitable counterhold wrench remove the camshaft sprocket.

CAUTION: Be careful not to damage the cylinder head with the wrench.

7. Remove the crankshaft sprocket from crankshaft.

INSTALLATION

NOTE: The piston in the No.1 cylinder must be at top dead center of the compression stroke.






1. Install damper pulley flange and crankshaft sprocket as shown. Pay close attention to their mounting direction.
2. Install the camshaft timing belt sprocket, then using a suitable counter hold wrench, tighten to 80-100 Nm (800-1000 kg. cm, 60-74 ft. lbs.)






3. Align mark on crankshaft sprocket to protrusion on front case.






4. Align the camshaft sprocket so that the hole in the sprocket web is on the top, and the marks on the sprocket align with the machined surface of the cylinder head.

NOTE: Mark on bearing cap must be visible through hole in sprocket.

5. Install the timing belt, then the timing belt tensioner
6. Tension the timing belt as follows:






a. Tension the timing belt by turning the timing belt tensioner pulley toward the water pump until a belt deflection of 4-6 mm(0.160-0.240 inch) under a force of 2 kg (4.4 lbs.) as shown in the illustration is achieved.
b. Tighten the tensioner bolt to 43-55 Nm (430-550 kg.cm, 32-41 ft. lbs.)
c. Turn the crankshaft one turn in operating direction (clockwise) and realign crankshaft sprocket timing mark.

CAUTION: Do not turn the crankshaft in a counterclockwise direction. The crankshaft should be turned smoothly.

d. Recheck the belt tension. The tension side of timing belt is pushed in horizontally with a moderate force, approximately 2 kg (20 N, 4.4 lbs.) the timing belt should deflect approximately 4-6 mm (0.160-0.240 inch).

NOTE: Repeat above procedure until proper belt tension is reached.






7. Install the timing belt cover, tighten timing belt cover bolts to 8-10 Nm (80-100 kg.cm, 6-7.4 ft. lbs.)
10. Install the crankshaft pulley.

CAUTION: Make sure that the crankshaft sprocket pin fits the small hole in the pulley.

8. Tighten crankshaft pulley bolt to 170-180 Nm (1700-1800 kg.cm, 125-133 ft. lbs.)
9. Install the coolant pump pulley.






10. Install the drive belts and adjust the belt tension.







10. Install the cylinder head cover, then tighten bolts to 8-10 Nm (80-100 kg. cm, 6-7 ft. lbs.)
12. Install the spark plug cables, ignition coil assembly and cylinder head center cover.