Timing Belt Installation

1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the pulley.

(b) Using SST, install the nut.

SST 09960-10010 (09962-01000, 09963-00500)

Torque: 24 Nm (245 kgf-cm, 18 ft-lb)

2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the pulley.

(b) Install the timing pulley. facing the sensor side inward.

NOTICE: Do not scratch the sensor part of the crankshaft timing pulley.

3. INSTALL NO.2 IDLER PULLEY
(a) Install the pulley with the bolt.

Torque: 42 Nm (425 kgf-cm. 31 ft-lb)

HINT: Use a bolt 35 mm (1.38 in.) in length.

(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING
(a) Align the bracket pin hole the pivot pin.

(b) Install the pulley with the bolt. Do not tighten the bolt yet.

HINT: Use a bolt 42 mm (1.65 in.) in length.

(c) Install the tension spring.

(d) Pry the pulley toward the left as far as it will go and tighten the bolt.
(e) Check that the idler pulley moves smoothly.
5. TEMPORARILY INSTALL TIMING BELT

NOTICE: The engine should be cold.

(a) Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body.
(b) Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley, No.2 idler pulley and keep them clean.
(c) Install the timing belt on the crankshaft timing pulley, oil pump pulley, No.1 idler pulley. water pump pulley and No.2 idler pulley.

HINT (When re-using timing belt): Align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

6. INSTALL TIMING BELT GUIDE
- Install the guide. facing the cup side outward.
7. INSTALL NO.1 TIMING BELT COVER
(a) Check that the timing belt cover gasket has no cracks or peeling, etc.
If the gasket has cracks or peeling, etc., replace it using these steps:
- Using a screwdriver and gasket scraper, remove all the old gasket material.
- Thoroughly clean all components to remove all the loose material.

- Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration.
- After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover.

(b) Install the timing belt cover with the 4 bolts.
(c) Install the 2 clamps of the crankshaft position sensor to the timing belt cover.
8. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST (and bolt), install the pulley bolt.

SST 09213-54015 (91651-60855 for Type A), 09330-00021 Bolt: Part No.91121-40665 for Type B

Torque: 108 Nm (1,100 kgf-cm, 80 ft-lb)

9. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of the pulley. and slide on the timing pulley.

(b) Using SST, install the bolt.

SST 09249-63010, 09960-10010 (09962-01000, 09963-01000)

Torque:
54 Nm (550 kgf-cm, 40 ft-lb)
37 Nm (380 kgf-cm, 27 ft-lb) for SST

HINT: Use a torque wrench with a fulcrum length of 340 cm (13.39 in.).

10. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.

(b) Using SST, turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap.

SST 09960-10010 (09962-01000, 09963-01000)

11. INSTALL TIMING BELT

HINT (When re-using timing belt):

- Check that the matchmarks on the timing belt matches the end of the No.1 timing belt cover.
If the matchmarks does not align, shift the meshing of the timing belt and crankshaft timing pulley until they align.

- Align the matchmarks of the timing belt and camshaft timing pulley.

(a) Remove any oil or water on the camshaft timing pulley, and keep it clean.

(b) Connect the timing belt to the camshaft timing pulley. and checking the tension between the crankshaft timing pulley and camshaft timing pulley.
12. CHECK VALVE TIMING

(a) Loosen the No.1 idler pulley bolt 1/2 turn.

(b) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

NOTICE: Always turn the crankshaft clockwise.

(c) Check that each pulley aligns with the timing marks as shown in the illustration.
If the timing marks do not align, remove the timing belt and reinstall it.

(d) Slowly turn the crankshaft pulley 1 and 7/8 revolutions, and align its groove with the mark at 45° BTDC (for No.1 cylinder) of the No.1 timing belt cover.

NOTICE: Always turn the crankshaft clockwise.

(e) Torque the mounting bolt of the No.1 idler pulley.

Torque: 42 Nm (425 kgf-cm. 31 ft-lb)

13. INSTALL NO.2 TIMING BELT COVER
(a) Check that the timing belt cover gaskets have no cracks or peeling, etc.
If the gasket has cracks or peeling, etc., replace it using these steps:
- Using a screwdriver and gasket scraper, remove all the old gasket material.
- Thoroughly clean all components to remove all the loose material.

(b) Disconnect the engine wire protector between the cylinder head cover and No.3 timing belt cover.
(c) Install the belt cover with the 4 bolts.

(d) Install the engine wire protector to the 2 mounting bolts of the No.2 timing belt cover in the sequence shown.
(e) Install the engine wire protector to the generator bracket and adjusting bar with the 2 bolts.
14. INSTALL SPARK PLUGS
(a) Install the 4 spark plugs.
(b) Connect the 4 high-tension cords to the spark plugs.
(c) Install the 4 high-tension cords to the clamp on the cylinder head cover.

15. INSTALL RH ENGINE MOUNTING BRACKET
- Install the mounting bracket with the 3 bolts.

Torque: 52 Nm (530 kgf-cm. 38 ft-lb)

HINT: Raise the engine as far as it will go, and place the mounting bracket in position.

16. INSTALL RH ENGINE MOUNTING INSULATOR
(a) Attach the mounting insulator to the body and mounting bracket with the 3 bolts and 2 nuts.
(b) Tighten the 2 bolts holding the mounting insulator to the body.

Torque: 64 Nm (650 kgf-cm, 47 ft-lb)

(c) Install the PS reservoir bracket with the bolt and nut.
(d) Install the PS reservoir to the reservoir bracket.
(e) Tighten the 2 nuts and bolt holding the mounting insulator to the mounting bracket.

Torque:
Bolt - 37 Nm (380 kgf-cm, 27 ft-lb)
Nut - 52 Nm (530 kgf-cm, 38 ft-lb)

17. CONNECT GROUND STRAP CONNECTOR

18. INSTALL PS PUMP DRIVE BELT
- Install the drive belt with the adjusting bolt and pivot bolt.
19. INSTALL RH FRONT WHEEL
21. INSTALL GENERATOR
22. INSTALL RH ENGINE UNDER COVER