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S7B31C06
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Timing System

Tools Required

Engine Fixture EN-48356
Flywheel Locking Device KM-6625
Fixing Rod KM-6333
Locking Tool KM-6628-A
Locking Tool KM-6340

Removal Procedure

  1. Disconnect the battery negative cable.
  2. Remove the air cleaner assembly. Refer to “Air Cleaner Assembly” in this section.
  3. Install the engine fixture (EN-48356).

    4. T8B11C09
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  4. Remove the accessory belt. Refer to “Accessory Belt and Tensioner” in this section.
  5. Remove the accessory belt tensioner. Refer to “Accessory Belt and Tensioner” in this section.

    6. T8B11C49
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  6. Rotate the crankshaft pulley clockwise.
  7. Align the notches between the pulley and the cover.

    8. T8B11C50
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  8. Remove the transmission tightening bolt.
  9. Install the flywheel locking device(KM-6625) to block the crankshaft.
  10. Install the transmission tightening bolt.

    11. T8B11C48
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  11. Remove the cylinder head cover. Refer to “Cylinder Head Cover” in this section.
  12. Remove the engine mount. Refer to “Engine Mount” in this section.

    13. T8B11C51
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  13. Remove the crankshaft pulley.
  14. Remove the timing belt upper cover.
  15. Remove the engine mount bracket.
  16. Remove the timing belt lower cover.
  17. Remove the timing belt center cover.

    18. T8B11C10
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  18. Install the fixing rod(KM-6333)(a) during rotating the timing belt tensioner.
  19. Remove the timing belt.

    20. T8B11C52
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  20. Remove the timing belt tensioner.
  21. Remove the timing belt idler.

T8B11C53
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Adjustment

  1. Align the both camshaft horizontally to install the camshaft rear locking tool (KM-6628-A).
  2. Confirm the both camshaft sprocket spot aligned.

    3. T8B11C54
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  3. Prepare the right half of locking tool(KM-6340).

    4. Notice : Recognizable from the lettering “Right”

  4. Unscrew the bolts(1) and detach front panel(2) from KM-6340-Right.

    5. T8B11C55
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    Important : The spot-type marking(4) on the intake camshaft sprocket does not correspond to the groove of KM-6340-Left during this process but must be somewhat above as shown.

  5. Confirm aligning between the intake side spot(3) and the exhaust side spot(4) on the camshaft sprockets as shown.
  6. If not aligned as shown, remove and install the camshaft sprocket to align. Refer to “Camshaft Sprocket” in this section.
  7. Insert the left of KM-6340(1) into the intake camshaft sprocket side.
  8. Insert the right of KM-6340(2) into the exhaust camshaft sprocket side.

    9. T8B11C56
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    Caution : If not aligned the notches, rotate the crankshaft until aligning after remove the flywheel locking device KM-6625 certainly.

  9. Confirm align the notches between the crankshaft sprocket and the cover.

    10. T8B11C52
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  10. Install the timing belt idler.

    11. Tighten
    Tighten the timing belt idler bolt to 50 N•m (36.8 lb-ft).

  11. Install the timing belt tensioner.

    12. Tighten
    Tighten the timing belt tensioner bolt to 55 N•m (40.6 lb-ft).


    T8B11C10
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  12. Install the timing belt adjust. Refer to “Timing System-Adjustment” in this section.
  13. Pull out the fixing rod(KM-6333)(a).

T8B11C51
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Installation Procedure

  1. Install the timing belt center cover.
  2. Install the timing belt lower cover.

    3. Tighten
    Tighten the timing belt lower cover bolts to 6 N•m (53.1 lb-in).

  3. Install the engine mount bracket.

    4. Tighten
    Tighten the engine mount bracket bolt to 65 N•m (47.9 lb-ft).

  4. Install the timing belt upper cover.

    5. Tighten
    Tighten the timing belt upper cover bolts to 4 N•m (35.4 lb-ft).

  5. Install the crankshaft pulley with aligning crankshaft pulley notches.

    6. Tighten
    Tighten the crankshaft pulley bolt to 25 N•m (18.4 lb-ft).


    T8B11C48
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  6. Install the engine mount. Refer to “Engine Mount” in this section.
  7. Install the cylinder head cover. Refer to “Engine Mount” in this section.

    8. T8B11C09
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  8. Install the accessory belt. Refer to “Accessory Belt and Tensioner” in this section.
  9. Install the accessory belt tensioner. Refer to “Accessory Belt and Tensioner” in this section.

    10. T8B11C50
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  10. Remove the transmission tightening bolt.
  11. Remove the flywheel locking device(KM-6625) to block the crankshaft.
  12. Install the transmission tightening bolt.

    13. Tighten
    Tighten the transmission tightening bolt to 60 N•m (44.2 lb-ft).


    S7B31C06
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  13. Remove the engine fixture (EN-48356).
  14. Install the air cleaner assembly. Refer to “Air Cleaner Assembly” in this section.
  15. Connect the battery negative cable.

T8B11C11
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Camshaft Sprocket

Removal Procedure

  1. Remove the timing belt. Refer to “Timing System” in this section.
  2. Remove the camshaft sprocket bolt cap.
  3. Remove the camshaft sprocket bolts.
  4. Remove the camshaft sprockets.

T8B11C11
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Installation Procedure

    Important : When installing the camshaft sprockets, the timing adjustment procedure must be accomplished. Refer to “Timing System-Adjustment” in this section.

  1. Install the camshaft sprockets.
  2. Install the camshaft sprocket bolts.

    3. Tighten
    Tighten the camshaft sprocket bolts to 65 N•m (47.9 lb-ft).

  3. Install the camshaft sprocket bolt caps.

    4. Tighten
    Tighten the camshaft sprocket bolt cap to 50 N•m (36.8 lb-ft).

  4. Install the timing belt. Refer to “Timing System” in this section.

T8B11C57
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Camshaft Adjuster

Removal and Installation Procedure

  1. Remove the camshaft adjuster bolts.

    2. Tighten
    Tighten the camshaft adjuster bolts to 65+120°+15° N•m (47.9+120°+15° lb-ft).

  2. Remove the camshaft adjusters.

    3. T8B11C58
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    Important : Don’t be confused the location and direction of the intake/exhaust adjusters.


T8B11C11
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Camshaft Seal Ring

Tools Required

Installer KM-422

Removal Procedure

  1. Remove the camshaft sprocket. Refer to “Camshaft Sprocket” in this section.

    2. T8B11C59
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    Caution : Extremely take care of contacting of camshaft surface. If damaged on the camshaft surface, engine oil could be leaked.

  2. Remove the camshaft seal ring.

T8B11C59
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Installation Procedure

    Notice : Don’t use camshaft seal ring again.

  1. Install the camshaft seal ring with new one.

    2. T8B11C60
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  2. Install the installer KM-422(3) with shims(2) with a total thickness of approx. 10mm and tighten the camshaft bolt(1) manually.
  3. Remove the installer KM-422.

T8B11C11
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Camshaft

Removal Procedure

    Caution : Take extreme care to prevent any scratches, nicks or damage to the camshafts and caps bearing surfaces. If scratched, damage may happen to engine.

  1. Remove the camshaft sprocket. Refer to “Camshaft Sprocket” in this section.
  2. Remove the timing belt tensioner. Refer to “Timing System” in this section.

    3. T8B11C12
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  3. Remove the timing belt rear cover.

    4. T8B11C18
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  4. Remove the camshaft position solenoid valve housing.
  5. Remove the camshaft cap bolts in this sequence (1)-(4)-(2)-(3).
  6. Remove the camshaft caps.

    7. T8B11C19
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  7. Remove the intake/exhaust camshafts with the seal rings.

T8B11C19
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Installation Procedure

  1. Coat/Lubricate the camshaft bearing and cam surfaces with clean engine oil.
  2. Install the camshafts on the cylinder head.

    3. T8B11C24
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    Important : It is essential to ensure that no sealant is applied outside the marked sealing areas.

  3. Apply surface sealant(LOCTITE 574) to sealing surfaces(1) of the 1st camshaft bearing cap thinly and evenly.

    4. Notice : The grooves (1) adjacent to the sealing surfaces must remain free from sealant.


    T8B11C18
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  4. Install the camshaft bearing caps in this sequence (2)-(3)-(1)-(4).
  5. Install the camshaft position solenoid valve housing.

    6. Tighten
    Tighten the camshaft bearing cap bolts to 8 N•m (70.8 lb-in).

  6. Install the new camshaft oil seal rings using by Installer(KM-422). Refer to “Camshaft Seal Ring” in this section.

    7. T8B11C12
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  7. Install the timing belt rear cover.

    8. Tighten
    Tighten the timing belt rear cover bolts to 6 N•m (53.1 lb-in).


    T8B11C11
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  8. Install the timing belt tensioner. Refer to “Timing System” in this section.
  9. Install the camshaft sprocket. Refer to “Camshaft Sprocket” in this section.

T8B11C19
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Valve Train - Cylinder Head Installed -

Tools Required

Universal Valve Spring Compressor EN-49074
Valve Spring Compressing Adapter EN-49155
Adapter-Cylinder Pressure EN-49154
Suction Device KM-845

Removal Procedure

  1. Remove the camshaft. Refer to “Camshaft” in this section.

    2. T8B11C25
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    Caution : Do not scratch on the valve tappet. And it must not be used by gloves or tools except special service tools.

  2. Remove the valve tappet using by suction device(KM-845).

    3. T8B52C61
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  3. Remove the spark plugs and then install the cylinder pressure adapter(EN-49154).

    4. Caution : Don’t stop this procedure until complete. If stop the applying the compressed air, cylinder head removal procedure should be accomplished.

  4. Apply the compressed air to the adapter to avoid dropping of valves in the cylinders inside.
  5. Install the universal valve spring compressor(EN–49074) and adapter(EN-49155).

    6. T8B11C61
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  6. Remove the valve key.
  7. Remove the valve springs, retainers, and seals.
  8. Remove the universal valve spring compressor(EN–49074) and adapter(EN-49155).

T8B11C61
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Installation Procedure

  1. Install the seals, retainers, and valve springs.
  2. Install the universal valve spring compressor(EN–49074) and adapter(EN-49155).
  3. Install the valve key.
  4. Install the valve spring, retainer, and seal.

    5. T8B11C25
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    Caution : Do not scratch on the valve tappet. And it must not be used by gloves or tools except special service tools when remove and install.

  5. Install the valve tappet using by suction device(KM-845).

    6. T8B11C19
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  6. Install the camshaft. Refer to “Camshaft" in this section.

T8B11C08
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Valve Clearance

Measurement

  1. Remove the cylinder head cover. Refer to “Cylinder Head Cover” in this section.

    2. T8B11C49
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  2. Rotate the crankshaft pulley clockwise.
  3. Align the notches between the pulley and the cover.

    4. T8B11C68
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  4. Measure the valve clearance (b) and (g). Rotate the crankshaft pulley clockwise through 180°.
  5. Measure the valve clearance (c) and (f). Rotate the crankshaft pulley clockwise through 180°.
  6. Measure the valve clearance (d) and (e). Rotate the crankshaft pulley clockwise through 180°.
  7. Measure the valve clearance (a) and (h). Rotate the crankshaft pulley clockwise through 180°.
  8. If the measured values are out-of-specifications, replace the new valve tappets.

  9. Determine the tappet size. Refer to “Valve Clearance-Determine Tappet Size” in this section.
  10. Replace the valve tappets if necessary. Refer to “Valve Train (Cylinder Head Installed)” in this section.

T8B11C69
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Determine Tappet Size

  1. Remove the tappet of out-of-specifications.
  2. Read ID number the tappet inside.
  3. Find the value(a) the ID number as below table.
  4. Calculate:
    5. Value(a)+Measured Value-Nominal Value = X
  5. Find the ID number through Value X as below table.
    6. 3.20+0.31-0.25 = 3.265mm -> 27X(ID number) ->55353766(Parts Number)
    .
    Parts Number
    ID Number
    Values(a)
    1
    24465260
    04
    3.060 - 3.050
    2
    24465261
    06
    3.050 - 3.070
    3
    24438041
    08
    3.070 - 3.090
    4
    24438145
    10
    3.090 - 3.110
    5
    24438146
    12
    3.110 - 3.130
    6
    24438147
    14
    3.130 - 3.150
    7
    24438148
    16
    3.150 - 3.170
    8
    24438149
    18
    3.170 - 3.190
    9
    24438150
    20
    3.190 - 3.210
    10
    24438151
    22
    3.210 - 3.230
    11
    55353764
    24X
    3.230 - 3.244
    12
    55353765
    25X
    3.244 - 3.258
    13
    55353766
    27X
    3.258 - 3.272
    14
    55353767
    28X
    3.272 - 3.286
    15
    55353768
    30X
    3.286 - 3.300
    16
    55353769
    31X
    3.300 - 3.314
    17
    55353770
    32X
    3.314 - 3.328
    18
    55353771
    34X
    3.328 - 3.342
    19
    55353772
    35X
    3.342 - 3.356
    20
    55353773
    36X
    3.356 - 3.370
    21
    55353774
    38X
    3.370 - 3.384
    22
    55353775
    39X
    3.384 - 3.398
    23
    55353776
    41X
    3.398 - 3.412
    24
    55353777
    42X
    3.412 - 3.426
    25
    55353778
    43X
    3.426 - 3.440
    26
    55353779
    45
    3.440 - 3.460
    27
    55353780
    47
    3.460 - 3.480
    28
    55353781
    49
    3.480 - 3.500
    29
    55353782
    51
    3.500 - 3.520
    30
    55353783
    53
    3.520 - 3.540

    .
    Parts Number
    ID Number
    Values(a)
    31
    55353784
    55
    3.540 - 3.560
    32
    55353785
    57
    3.560 - 3.580
    33
    55353786
    59
    3.580 - 3.600


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