Timing Belt Auto-Tensioner Removal and Installation
1. Timing Belt - Remove

Remove the timing belt.

2. Battery Clamp Bolt - Remove
Remove the battery clamp bolt from the back cover.


3. Timing Belt Auto-Tensioner - Remove
Remove the timing belt auto-tensioner.



NOTE: Clean the timing belt pulleys, the timing belt guide plate, and the upper and lower covers.

1. Timing Belt Auto-Tensioner - Install
1.
Align the holes on the rod and the housing of the timing belt auto-tensioner.
2.
Use a hydraulic press to slowly compress the timing belt auto-tensioner. Insert a 2.0 mm (5/64 in) pin through the housing and the rod.
NOTE: The compression pressure should not exceed 9,800 N (999.3 kgf, 2,203.1 lbf).
3.
Install the timing belt auto-tensioner.
NOTE: Make sure the pin stays in place.

2. Timing Belt Adjuster - Hold
Thread the battery clamp bolt in as shown to hold the timing belt adjuster in its current position. Tighten it by hand, do not use a wrench.


3. No. 1 Piston at Top Dead Center - Set (Crank Side)
Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump.


4. No. 1 Piston at Top Dead Center - Set (Cam Side)

FRONT

REAR
Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.


5. Idler Pulley - Loosely Install
Loosely install the idler pulley (A) with a new idler pulley bolt (B) so the pulley can move but does not come off.


6. Timing Belt - Install
Install the timing belt in a counterclockwise sequence starting with the drive pulley. Take care not to damage the timing belt during installation:
-1.
Drive pulley (A)
-2.
Idler pulley (B)
-3.
Front camshaft pulley (C)
-4.
Water pump pulley (D)
-5.
Rear camshaft pulley (E)
-6.
Adjusting pulley (F)

7. Idler Pulley Bolt - Tighten
Tighten the idler pulley bolt.


8. Pin - Remove
Remove the pin from the timing belt auto-tensioner.


9. Battery Clamp Bolt - Remove
Remove the battery clamp bolt from the back cover.


10. Side Engine Mount Bracket - Install
Install the lower half of the side engine mount bracket using new bolts (A) and the bolt (B).


11. Timing Belt Guide Plate - Install
Install the timing belt guide plate (A) as shown.


12. Lower Cover - Install
Install the lower cover.


13. Upper Cover - Install
Install the front upper cover (A) and the rear upper cover (B).


14. Side Engine Mount Bracket - Install

Install the upper half of the side engine mount bracket.

15. Crankshaft Pulley - Install

Install the crankshaft pulley.

16. Camshaft Timing - Check
1.
Rotate the crankshaft pulley about six turns clockwise so the timing belt positions itself on the pulleys.
2.
Turn the crankshaft pulley so its white mark (A) lines up with the pointer (B).
NOTE: The other pointer (C) is not used.




FRONT

REAR
3.
Check the camshaft pulley marks.
NOTE: If the marks are not aligned, rotate the crankshaft 360 degrees, and recheck the camshaft pulley mark:
If the camshaft pulley marks are at TDC, go to drive belt auto-tensioner install.
If the camshaft pulley marks are not at TDC, remove the timing belt and reinstall the timing belt.

17. Drive Belt Auto-Tensioner - Install

Install the drive belt auto-tensioner.

18. Engine Undercover - Install

Install the engine undercover.

19. Right Front Wheel - Install

Install the right front wheel.