Repair Procedures: Removal

Engine removal is not required for this procedure.

1. Loosen the water pump pulley bolt and the drive idler mounting bolt.
2. Loosen the alternator tension adjusting bolt (A) to loosen tension.
   Fig 1: Identifying Alternator Tension Adjustment Bolt

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3. Remove the alternator drive belt (A).
   Fig 2: Alternator Drive Belt Routing

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4. Remove the alternator (A). (Refer to ALTERNATOR )
   Fig 3: Identifying Alternator

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5. Remove the RH front wheel.
6. Remove the engine mounting bracket (B).
   Fig 4: Identifying Engine Mounting Bracket

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   NOTE: Support the engine with a jack not to be tilted.
7. Remove the alternator bracket (B).
8. Remove the engine support bracket (A).
   Fig 5: Identifying Alternator Bracket & Engine Support Bracket

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9. Remove the water pump pulley (A).
   Fig 6: Identifying Water Pump Pulley

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10. Remove the water pump (A).
    Fig 7: Identifying Water Pump

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11. Remove the drive belt idler (A).
    Fig 8: Identifying Drive Belt Idler

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12. Disconnect the ignition coil connector (A) and the breather hose (B).
    Fig 9: Identifying Ignition Coil Connector & Breather Hose

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13. Disconnect the positive crankcase ventilation (PCV) hose (A) and PCSV hose (B).
    Fig 10: Identifying Positive Crankcase Ventilation Hose & PCSV Hose

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14. Remove the ignition coils (A).
    Fig 11: Identifying Ignition Coils

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15. Remove the cylinder head cover (A) with its gasket (B).
    Fig 12: Identifying Cylinder Head Cover & Gasket

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16. Remove side cover.
    Fig 13: Identifying Side Cover

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17. Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.
    Fig 14: Aligning Groove Of Crankshaft Pulley With Timing Mark Of Timing Chain Cover

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18. Remove the crankshaft bolt (B) and crankshaft pulley (A).
    Fig 15: Identifying Crankshaft Bolt & Crankshaft Pulley

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    NOTE:

    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.
      Fig 16: Identifying SST (09231-2B100) Holding Ring Gear

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    • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.

    1. Remove the bracket (A).
       Fig 17: Identifying Bracket

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    2. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the transaxle mounting bolt (B).
       Fig 18: Identifying Dust Cover

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    3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
    4. Adjust the angle of the links (D) so that the bolt 70 mm (2.7559 in.) can be fastened to the original mounted hole.
       Fig 19: Identifying Ring Gear, Holder, Links & Nuts

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    5. Install the SST (09231-3D100) using the mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
       Fig 20: Identifying SST (09231-3D100) Holding Ring Gear

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19. Remove the timing chain cover (A).
    Fig 21: Identifying Timing Chain Cover

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20. Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No. 1 cylinder be positioned at TDC.
    1. Check the dowel pin of the crankshaft for facing upside of the engine at this moment.
       CAUTION: Put paint marks on the timing chain links (3 places) that meet with the timing marks of the camshaft sprockets and the crankshaft sprocket.
    Fig 22: Aligning Timing Marks

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21. Remove the hydraulic tensioner (A).
    Fig 23: Identifying Hydraulic Tensioner & Hole

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    CAUTION: Before removing the tensioner, fix the piston of the tensioner with a pin through the hole (B) at TDC.
22. Remove the timing chain tensioner arm (A) and guide (B).
    Fig 24: Identifying Timing Chain Tensioner Arm & Guide

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23. Remove the timing chain (A).
    Fig 25: Identifying Timing Chain

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