Installation

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. Install the timing pulley, facing the sensor side inward.

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

c. Install the timing belt plate with the bolt.

Torque: 8 Nm (69 inch lbs.)





2. Install No.1 idler pulley.

Adhesive: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent

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

Torque: 34 Nm (25 ft. lbs.)

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 (32 ft. lbs.)

b. Check that the idler pulley moves smoothly.





4. Install Rh camshaft timing pulley.
a. Face the flange side of the timing pulley outward.
b. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley.
c. Using SST, install the pulley bolt.
SST 09249 - 63010, 09960 - 10010 (09962 - 01000, 09963 - 01000)

Torque: 88 Nm (65 ft. lbs.)

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





5. Install LH camshaft timing pulley.
a. Face the flange side of the timing pulley inward.
b. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley.
c. Using SST, install the pulley bolt.
SST 09960 - 10010 (09962 - 01000, 09963 - 01000)

Torque: 125 Nm (94 ft. lbs.)





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 timing marks of the crankshaft timing pulley and oil pump body.





b. Camshaft Timing Pulley Positions: Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover.
SST 09960 - 10010 (09962 - 01000, 09963 - 01000)





7. Install timing belt.

NOTICE: The engine should be cold.

a. Remove any oil or water on the pulleys, and keep them clean.

NOTICE: Only wipe the pulleys; do not use any cleansing agent.

b. Face the front mark on the timing belt forward.
c. Align the installation mark on the timing belt with the timing 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 in this order:
1) Crankshaft timing pulley
2) Water pump pulley
3) LH camshaft timing pulley
4) No.2 idler pulley
5) RH camshaft timing pulley
6) No.1 idler pulley





8. Set timing belt tensioner.
a. Using a press, slowly press in the push rod using 981 - 9,807 N (200 - 2,205 lbs.) 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 (20 ft. lbs.)

c. Remove the 1.27 mm hexagon wrench from the tensioner.





10. Check valve timing.
a. Slowly turn the crankshaft 2 revolution, and align the timing marks of the crankshaft timing pulley and oil pump body.

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 timing 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 Rh engine mounting bracket.

Torque: 28 Nm (21 ft. lbs.)





12. Install No.2 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 5 bolts.

Torque: 8.5 Nm (74 inch lbs.)

c. Install the engine wire protector clamp to the No.3 timing belt cover.
d. Install the engine wire protector to the No.3 timing belt cover with the bolt.





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





14. Install no.1 timing belt cover.
a. Check that the timing belt cover gaskets have 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.

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

- 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.

Torque: 8.5 Nm (74 inch lbs.)





15. Install crankshaft pulley.
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213 - 54015 (91651 - 60855), 09330 - 00021

Torque: 215 Nm (159 ft. lbs.)

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

Torque: (Nut): 28 Nm (21 ft. lbs.)

17. Install No. 2 RH engine mounting bracket, engine moving control rod and RH engine mounting stay
18. Connect ground strap connectors.
19. Connect engine coolant reservoir hose to water outlet.
20. Install PS pump drive belt.
21. Install generator drive belt.
22. Install RH fender apron seal.
23. Install RH front wheel.
24. Vehicle road test.
Check for abnormal noise, shock, slippage, correct shift points and smoothly operation.