Page 65 of 4770
(c) Install the gasket to the head cover.
(d) Install the head cover with the 4 grommets and nuts.
Uniformly tighten the nuts in several passes.
Torque: 23 N±m (230 kgf±cm. 17 ft±lbf)
HINT: Install the grommets so that their markings are
as shown in the illustration.
(e) Tighten the 2 wire harness clamp (No.2 timing belt
cover) mounting bolts.
(f) Connect the PCV hoses.
7. RECONNECT HIGH±TENSION CORDS TO SPARK
PLUGS(c) Install a new adjusting shim.
wPlace a new adjusting shim on the valve lifter.
wUsing SST (A), press down the valve lifter and
remove SST (B).
SST 09248±50020 (09248±05011, 09248±05021)
(d) Recheck the valve clearance.
6. REINSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in
the illustration.
Seal pecking:
Part No.08826±00080 or equivalent
± 5S±FE ENGINEENGINE MECHANICALEG1±15
Page 75 of 4770
TIMING BELT
COMPONENTS FOR REMOVAL AND
INSTALLATION
± 5S±FE ENGINEENGINE MECHANICALEG1±25
Page 76 of 4770
TIMING BELT REMOVAL
(See Components for Removal and Installation)
1. DISCONNECT NEGATIVE (±) TERMINAL CABLE
FROM BATTERY
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the 'LOCK'
position and the negative (±) terminal cable is discon±
nected from the battery.
2. REMOVE ENGINE COOLANT RESERVOIR TANK
(a) Disconnect the reservoir hose.
(b) While pushing the tab of the bracket, remove the
reservoir tank.
3. REMOVE GENERATOR (See page CH±10)
4. REMOVE RH FRONT WHEEL
5. REMOVE RH FENDER APRON SEAL
8. REMOVE ENGINE MOVING CONTROL ROD
Remove the 3 bolts and control rod.
9. DISCONNECT CONNECTOR FROM GROUND WIRE
ON RH FENDER APRON7. SLIGHTLY JACK UP ENGINE
Raise the engine enough to remove the weight from
the engine mounting on the right side. 6. REMOVE PS DRIVE BELT
Loosen the 2 bolts, and remove the drive belt.
± 5S±FE ENGINEENGINE MECHANICALEG1±26
Page 77 of 4770
11. REMOVE SPARK PLUGS
(a) Disconnect the high ± tension cords at the rubber
boot.
DO NOT pull on the cords.
NOTICE: Pulling on or bending the cords may damage the
conductor inside.
13. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with
timing mark ª0º of the No.1 timing belt cover. 12. REMOVE NO.2 TIMING BELT COVER
Remove the 5 bolts, timing belt cover and 2 gaskets.10. REMOVE No.2 ENGINE MOUNTING BRACKET
Remove the 3 bolts and mounting bracket.
(b) Using a 16 mm plug wrench, remove the spark plug.
± 5S±FE ENGINEENGINE MECHANICALEG1±27
Page 78 of 4770
14. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
HINT (When re±using timing belt): Place the match±
marks on the timing belt and camshaft timing pulley,
and place matchmark on timing belt to match the end
of the No.1 timing belt cover.
15. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the bolt, plate washer and timing
pulley.
SST 09249±63010 and 09278±54012(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 one revolution (360'*).
(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.
± 5S±FE ENGINEENGINE MECHANICALEG1±28
Page 79 of 4770
HINT (When re±using timing belt): After loosening
the crankshaft pulley bolt, check that the timing belt
matchmark aligns with the end of the No. 1 timing belt
cover when the crankshaft pulley groove is aligned
with the timing mark ª0º of the No. 1 timing belt cover.
If the matchmark does not align, align as follows:
When matchmark is misaligned counterclockwise:
wAlign the rnatchmarks by pulling the timing belt up
on the No.1 idler pulley side while turning the
crankshaft pulley clockwise. When matchmark is misaligned clockwise:
wAlign the matchmark by pulling the timing belt up
on the water pump pulley side while turning the
crankshaft pulley counterclockwise.
wAfter aligning the matchmark, hold the timing
belt, turn the crankshaft pulley clockwise, and
align its groove with timing mark ª0º of the No.1
timing belt cover. 16. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213±54015 (91651± 60855),
09330±00021
± 5S±FE ENGINEENGINE MECHANICALEG1±29
Page 80 of 4770
(b) Using SST, remove the pulley.
SST 09213±60017 (09213±00020, 09213±00030,
09213±00060)
HINT (When re±using timing belt): Remove the pulley
without turning it.
19. 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.wAfter aligning the matchmark, hold the timing
belt, turn the crankshaft pulley counterclockwise,
and align its groove with timing mark ª0º of the
No.1 timing belt cover.
17. REMOVE No.1 TIMING BELT COVER
Remove the 4 bolts, timing belt cover and gasket.
18. REMOVE TIMING BELT GUIDE
± 5S±FE ENGINEENGINE MECHANICALEG1±30
Page 81 of 4770
TIMING BELT COMPONENTS INSPECTION
1. INSPECT TIMING BELT
NOTICE:
wDo not bend, twist or turn the timing belt Inside out.
wDo not allow the timing belt to come into contact
with oil, water or steam.
22. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use 2 screw±
drivers.
HINT: Position shop rags as shown to prevent
damage.20. REMOVE NO.1 IDLER PULLEY AND TENSION
SPRING
Remove the bolt, pulley and tension spring.
23. REMOVE OIL PUMP PULLEY
Using SST, remove the nut and pulley.
SST 09616±3001121. REMOVE NO.2 IDLER PULLEY
Remove the bolt and pulley.
± 5S±FE ENGINEENGINE MECHANICALEG1±31