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 09960-10010 (09962-01000, 09963-00500) install the pulley nut.
Torque: 28 Nm (21 ft lb)
2. Install crankshaft timing pulley.
a. Align the timing pulley set key with the key groove of the pulley.
b. Slide on the timing pulley, facing the flange side inward.
3. Install No. 2 idler pulley.
a. Install the pulley with the bolt.
Torque: 42 Nm (31 ft lb)
NOTE: Use the 35 mm (1.38 in.) long bolt.
b. Check that the idler pulley moves smoothly.
4. Temporarily install No. 1 idler pulley and tension spring.
a. Align the bracket pin hole with the pivot pin.
b. Install the pulley with the bolt. Do not tighten the bolt yet.
NOTE: Use the 42 mm (1.65 in.) long bolt.
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.
NOTE: 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 and 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.
NOTE (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 the timing belt guide, facing the cup side outward.
7. Install No. 1 timing belt cover.
a. Install the gasket to the timing belt cover.
b. Install the timing belt cover with the 4 bolts.
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 09213-54015 (91651-60855), 09330-00021 install the pulley bolt.
Torque: 108 Nm (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 09249 - 63010, 09960-10010 (09962-01000, 09963-01000) install the pulley bolt.
Torque:
54 Nm (40 ft lb)
37 Nm (27 ft lb) for SST
NOTE: Use a torque wrench with a fulcrum length of 340 mm (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 09960-10010 (09962-01000, 09963-01000) turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap.
11. Connect timing belt to camshaft timing pulley.
NOTE (When re-using timing belt):
^ Check that the matchmark on the timing belt matches the end of the No. 1 timing belt cover.
If the matchmark does not align. shift the meshing of the timing belt and crankshaft timing pulley until they align. (See step 19 in Timing Belt Removal)
^ 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 TDC to TDC.
NOTE: Always turn the crankshaft pulley 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.
NOTE: Always turn the crankshaft pulley clockwise.
e. Tighten the mounting bolt of the No. 1 idler pulley.
Torque: 42 Nm (31 ft lb)
13. Install No. 2 timing belt cover.
a. Install the gasket to the No. 1 timing belt cover.
b. Disconnect the engine wire protector between the cylinder head cover and No. 3 timing belt cover.
c. Install the belt cover with the 5 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.
14. Install spark plugs.
a. Using a 16 mm plug wrench, install the 4 spark plugs.
Torque: 18 Nm (13 ft lb)
b. Connect the 4 high-tension cords to the spark plugs.
15. Install the RH engine mounting bracket with the 3 bolts.
Torque: 52 Nm (38 ft lb)
NOTE: 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 (47 ft lb)
c. Install the PS reservoir bracket with the bolt and nut.
Torque: 28 Nm (21 ft lb) for 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 (27 ft lb)
Nut 52 Nm (38 ft lb)
17. Connect ground strap connector.
18. Install the PS pump drive belt with the adjusting bolt and pivot bolt.
19. Install RH front wheel.
20. Install generator.
a. Install the generator with the pivot bolt and adjusting lock bolt (with A/C) or adjusting bolt (with out A/C). Do not tighten the bolts yet.
b. Install the drive belt with the pivot bolt, adjusting lock bolt (with A/C) and adjusting bolt.
c. Adjust the drive belt.
d. Tighten the pivot bolt, adjusting lock bolt (with A/C) and adjusting bolt (with out A/C).
Torque:
Pivot bolt 54 Nm (40 ft lb)
Adjusting lock bolt (with A/C) or
Adjusting bolt (with out A/C) 19 Nm (14 ft lb)
e. Connect the generator connector.
f. Connect the generator wire with the nut and rubber cap.
g. Install the wire to the clamp on the rear end cover.
21. Install RH engine under cover.
22. Connect negative (-) terminal cable to battery.