Installation

COMPONENTS

TIMING BELT INSTALLATION

1. Install crankshaft timing pulley.
(a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley.

(b) Using SST and a hammer, tap in the timing pulley, facing the sensor side rearward. SST 09223-46011

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

(a) Using a 10 mm hexagon wrench, install the idler pulley with the plate washer and bolt.

Torque: 34 Nm (350 kgf-cm, 25 ft-lb)

(b) Check that the pulley bracket moves smoothly.

3. Install No.2 idler pulley.
(a) Install the idler pulley with the bolt.

Torque: 43 Nm (440 kgf-cm, 32 ft-lb)

(b) Check that the idler pulley moves smoothly.

4. Install RH camshaft timing pulley.
(a) Install the timing pulley, facing the flange side outward.

(b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown.

(c) Using SST, install and torque the bolt. SST 09249-63010,09960-10010 (09962-01000)

Torque: 88 Nm (900 kgf-cm, 65 ft-lb)

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

5. Install LH camshaft timing pulley.
(a) Install the timing pulley, facing the flange side inward.

(b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown.

(d) Using SST, install and torque the bolt. SST 09960-10010 (09962-01000)

Torque: 125 Nm (1.300 kgf-cm, 94 ft-lb)

6. Set No.1 cylinder to TDC/Compression.

(a) Crankshaft timing pulley position:
- Temporarily install the crankshaft pulley bolt to the crankshaft.
- Turn the crankshaft and align the crankshaft timing pulley groove with the oil pump alignment mark.

(b) RH camshaft timing pulley position:
Using SST, turn the camshaft pulley, align the timing marks of the camshaft and the No.3 timing belt cover. SST 09960-10010 (09962-01000)
(c) LH camshaft timing pulley position:
Using SST, turn the camshaft pulley, align the timing marks of the camshaft and the No.3 timing belt cover. SST 09960-10010 (09962-01000)

7. Install timing belt.

NOTICE: The engine should be cold.

(a) Remove any oil or water on the pulleys, and keep them clean.
(b) Check the timing belt front mark.

(c) Align the installation mark on the timing belt with the dot mark of the crankshaft timing pulley.
(d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

(e) Install the timing belt with the following order:
- Crankshaft timing pulley
- Water pump pulley
- LH camshaft timing pulley
- No.2 idler pulley
- RH camshaft timing pulley
- No.1 idler pulley

8. Set timing belt tensioner.
(a) Using a press, slowly press in the push rod using 981-9,807 N (100-1,000 kgf, 200-2,205 lb) of pressure.

(b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
(c) Release the press.

(d) Install the dust boot to the tensioner.

9. Install timing belt tensioner.

(a) Temporarily install the tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.

Torque: 27 Nm (280 kgf-cm, 20 ft-lb)

(a) Turn the crankshaft, and align the crankshaft liming pulley groove with the oil pump alignment mark.

NOTICE: Always turn the crankshaft clockwise.

(b) Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 liming belt cover as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
(c) Remove the crankshaft pulley bolt.

11. Install timing belt guide.
Install the belt guide, facing the cup side outward.

12. Install engine RH mounting bracket.
Install the mounting bracket with the 2 bolts and nut.

Torque: 28 Nm (290 kgf-cm, 21 ft-lb)

13. Install No.2 timing belt cover.
(a) Check that the timing belt cover gasket has no cracks or peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using following steps.
(1) Using a screwdriver and gasket scraper, remove all the old gasket material.
(2) Thoroughly clean all components to remove all the loose material.

(3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration.
(4) After installing the gasket, press down on it so that the adhesive firmly sticks to the belt cover.
(b) Install new gasket to the No.2 belt cover.

14. Connect engine wire.
(a) Connect the engine wire with the clamp.
(b) Install the bolt holding the engine wire to the No.3 timing belt cover.

15. Install No.1 timing belt cover.
(a) Check that the liming belt cover gaskets have cracks or peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using following steps.peeling, etc., replace them using following steps.
(1) Using a screwdriver and gasket scraper, remove all the old gasket material.
(2) Thoroughly clean all components to remove all the loose material.

(3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration.

NOTICE: When joining 2 gaskets. do not leave a gap between them. Cut off any excess gasket.

(4) After installing the gasket, press down on it so that the adhesive firmly sticks to the belt cover.
(b) Install new gaskets to the No.1 belt cover.

16. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, and slide the pulley.
(b) Using SST, install and torque the bolt. SST 09213-54015,09330-00021

Torque: 215 Nm (2,200 kgf-cm, 159 ft-lb)

17. Install No.2 generator bracket.
Install the bracket with the pivot bolt and nut. Do not tighten the bolt yet.

Torque: 28 Nm (290 kgf-cm, 21 ft-lb) for Nut

18. Install No.2 RH engine mounting bracket and engine moving control rod.
Install the mounting bracket and control rod with the 3 bolts.

Torque: 63.7 Nm (650 kgf-cm, 47 ft-lb)

19. Install RH engine mounting stay.
Install the mounting stay with the 3 bolts.

Torque: 31.4 Nm (320 kgf-cm, 23 ft-lb)

20. Connect ground straps.
Connect the 2 straps.

21. Install and adjust PS drive belt.
Install the drive belt with the pivot and adjusting bolts.

Drive belt tension:
New belt 150 - 185 lb
Used belt 115 ± 20 lb

22. Install generator drive belt.
Adjust the drive belt.

Drive belt tension:
New belt 175 ± 5 lb
Used belt 115 ± 20 lb

23. Install coolant reservoir tank.
24. Connect negative (-) terminal cable to battery.
25. Start engine, and check for abnormal noise and smooth operation.

26. Install RH fender apron seal.
27. Install RH front wheel.