Timing Belt Removal

COMPONENTS FOR REMOVAL AND INSTALLATION

1. REMOVE GENERATOR
2. REMOVE RH ENGINE UNDER COVER
3. REMOVE RH FRONT WHEEL

4. REMOVE PS PUMP DRIVE BELT
- Loosen the 2 bolts, and remove the drive belt.

5. SLIGHTLY JACK UP ENGINE
- Attach the jack to the oil pan (use wood block under pan), and raise the engine enough to remove the weight from the engine mounting on the right side.

6. DISCONNECT GROUND STRAP CONNECTOR
7. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Remove the bolt and 2 nuts holding the mounting insulator to the mounting bracket.
(b) Disconnect the PS reservoir from the reservoir bracket.

(d) Remove the 2 bolts and mounting insulator.

8. REMOVE RH ENGINE MOUNTING BRACKET
- Remove the 3 bolts and mounting bracket.

HINT: Raise the engine as far as it will go, and remove the mounting bracket.

9. REMOVE SPARK PLUGS
(a) Disconnect the 4 high-tension cords from the clamp on the cylinder head cover.
(b) Disconnect the 4 high-tension cords from the spark plug.
(c) Remove the 4 spark plugs.

10. REMOVE NO.2 TIMING BELT COVER
(a) Remove the 2 bolts, and disconnect the engine wire protector from the generator bracket and adjusting bar.

(b) Remove the 4 bolts and timing belt cover.
11. 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) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crankshaft one revolution (360°).

12. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEY

HINT (When re-using timing belt) Place matchmarks on the timing belt and camshaft timing pulley. and place matchmarks on timing belt to match the end of the No.1 timing belt cover.

(a) Loosen the mounting bolt of the No.1 idler pulley and shift the pulley toward the left as far as it will go and temporarily tighten it.
(b) Remove the timing belt from the camshaft timing pulley.

13. REMOVE CAMSHAFT TIMING PULLEY
- Using SST, remove the pulley bolt and timing pulley.

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

14. REMOVE CRANKSHAFT PULLEY
(a) Using SST (and bolt), remove the pulley bolt.

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

HINT:
- Either of 2 types of pulley may be used, each with its own bolt size, Type A and Type B.
- When using bolt Type B, a plate washer must be inserted between the bolt and SST.

HINT: (When re-using timing belt): After loosening the crankshaft pulley bolt, check that the timing belt matchmarks aligns with the end of the No.1 timing belt cover when the crankshaft pulley groove is aligned with the timing mark "0" of the No.1 timing belt cover. If the matchmarks does not align, align as follows:

When matchmarks is misaligned clockwise:

- Align the matchmarks by pulling the timing belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise.

- After aligning the matchmarks, hold the timing belt. turn the crankshaft pulley clockwise, and align its groove with timing mark "0" of the No.1 timing belt cover.

When matchmarks is misaligned counterclockwise:
- Align the matchmarks by pulling the timing belt up on the No.1 idler pulley side while turning the crankshaft pulley clockwise.

- After aligning the matchmarks, hold the timing belt, turn the crankshaft pulley counterclockwise, and align its groove with timing mark of the No.1 timing belt cover.

(b) Using SST, remove the pulley. SST 09950-50010(09951 -05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020 for Type A, 09954-05010 for Type B)

HINT: (When re-using timing belt) Remove the pulley without turning it.

15. REMOVE NO.1 TIMING BELT COVER
(a) Disconnect the 2 clamps of the crankshaft position sensor wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
16. REMOVE TIMING BELT GUIDE
17. REMOVE TIMING BELT

HINT: (When re-using timing belt) Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the timing belt and crankshaft timing pulley.

18. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING
19. REMOVE NO.2 IDLER PULLEY

20. REMOVE CRANKSHAFT TIMING PULLEY
- If the pulley cannot be removed by hand, use SST to remove the crankshaft timing pulley.

SST 09950-50010 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)

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

21. REMOVE OIL PUMP PULLEY
- Using SST, remove the nut and pulley.

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