Timing Belt Removal

REMOVAL
1. Remove generator.
2. Remove RH engine under cover.
3. Remove RH front wheel.
4. Remove Power Steering (PS) pump drive belt.





Loosen the pivot bolt and adjusting bolt, and remove the drive belt.





5. Slightly jack up engine.
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.





c. Remove the bolt, nut and PS 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 Top Dead Center (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 1 revolution (360°).
12. Remove timing belt from camshaft timing pulley.





HINT:
(When re-using timing belt): Place the matchmarks on the timing belt and camshaft timing pulley, and place matchmark on timing belt to match portion A 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.





a. Using Special Service Tool (SST) 09249 - 63010, 09960 - 10010 (09962 - 01000, 09963 - 01000) or equivalent, loosen the pulley bolt.
b. Remove the bolt and timing pulley.
14. Remove crankshaft pulley.





a. Using SST 09213 - 54015 (91651 - 60855 for type A), 09330 - 00021, (and bolt), loosen the pulley bolt.
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 matchmark aligns with portion A 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 matchmark does not align, align as follows:

When matchmark is misaligned clockwise:





1) Align the matchmark by pulling the timing belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise.





2) After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley clockwise, and align its groove with timing mark "O" of the No.1 timing belt cover.
When matchmark is misaligned counterclockwise:





1) Align the matchmark by pulling the timing belt up on the No.1 idler pulley side while turning the crank-shaft pulley clockwise.





2) After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley counterclockwise, and align its groove with timing mark "O" of the No.1 timing belt cover.
b. Remove the pulley bolt.





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

HINT:
- Either of 2 types of pulley may be used, each with its own bolt size, type A and type B.
- When re-using timing belt: Remove the pulley without turning it.





15. Remove NO.1 timing belt cover.
a. Disconnect the crankshaft position sensor wire from the clamp on the timing belt cover.
b. Disconnect the clamp of the crankshaft position sensor wire from the timing belt cover.
c. 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.
Remove the bolt, pulley and tension spring.
19. Remove NO.2 idler pulley.
Remove the bolt and pulley.
20. Remove crankshaft timing pulley.





If the pulley cannot be removed by hand, use SST 09950 - 50010 (09951 - 05010, 09952 - 05010, 09953 - 05010, 09953 - 05020, 09954 - 05010) to remove the timing pulley.

NOTICE: Do not scratch the angle sensor of the timing pulley.

21. Remove oil pump pulley.





a. Using SST 09960 - 10010 (09962 - 01000, 09963 - 00500), loosen the pulley nut.
b. Remove the nut and pulley.