Installation

TIMING BELT INSTALLATION





1. Install crankshaft timing pulley.
(a) Align the pulley set key with the key groove of the timing pulley.
(b) Slide on the liming pulley, facing the flange side inward.





2. Install No.1 idler pulley.
(a) Apply adhesive to two or three threads of the mount bolt end.

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

(b) Using a 10 mm hexagon wrench. install the idler pulley with the plate washer and bolt. Torque the bolt.

Torque: 34 Nm (350 kgf-cm, 25 ft-lb)

(c) Check that the pulley bracket moves smoothly.





3. Temporarily install timing belt.

NOTICE: The engine should be cold.

(a) Remove any oil or water on the crankshaft timing. No. 1 idler and water pump pulleys, and keep them clean.
(b) Align the installation mark on the timing belt with the drilled mark of the crankshaft timing pulley.
(c) Install the timing belt on the crankshaft timing, No.1 idler and water pump pulleys.





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





5. Install No.1 timing belt cover.
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the four bolts.





6. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, and slide the pulley.
(b) Using SST, install and torque the bolt. SST 09213-54015,09213-70010(90105-08076) 09330-00021

Torque: 245 Nm (2,500 kgf-cm, 181 ft-lb)





7. Install No.2 idler pulley.
(a) Install the idler pulley with the bolt. Torque the bolt.

Torque: 39 Nm (400 kgf-cm, 29 ft-lb)

(b) Check that the idler pulley moves smoothly.

8. Install LH camshaft timing pulley.
(a) Slide the timing pulley, facing the flange side outward.





(b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown.
(c) Install the knock pin.





(d) Using SST. install and torque the bolt. SST 09278-54012

Torque: 108 Nm (1,100 kgf-cm, 80 ft-lb)

9. Set No.1 cylinder to TDC/Compression.





(a) (Crankshaft Position)
Turn the crankshaft pulley, and align its groove with the "0", timing mark of the No.1 timing bell cover.





(b) (RH Camshaft Pulley Position)
Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No.3 timing belt cover.
(c) (LH Camshaft Pulley Position)
Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and No.3 timing belt cover.

10. Install timing belt to LH camshaft timing pulley.





(a) Check that the installation mark on the timing belt matches the end of the No.1 timing belt cover.
If the installation marks do not align, shift the meshing of the timing belt and crankshaft timing pulley until they align.





(b) Remove any oil or water on the LH camshaft timing pulley, and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley.SST 09278-54012





(d) Using SST, align the timing marks of the LH camshaft pulley and No.3 timing belt cover. SST 09278-54012
(e) Check that the timing belt has tension between the crankshaft timing and LH camshaft timing pulleys.

11. Install RH camshaft timing pulley and timing belt.
(a) Remove any oil or water on the RH camshaft timing and No.2 idler pulleys, and keep them clean.





(b) Align the installation mark on the timing belt with the timing mark of the RH camshaft timing pulley as shown.
(c) Hang the timing belt on the RH camshaft timing pulley, facing the flange side inward.





(d) Align the timing marks of the RH camshaft timing pulley and No.3 timing belt cover.
(e) Slide the RH camshaft timing pulley on the camshaft.





(f) Using SST, align the knock pin hole of the camshaft with the knock pin groove (3V mark side) of the pulley and install the knock pin. SST 09278-54012
(g) Using SST, install and torque the bolt. SST 09249-63010 and 09278-54012

Torque: 75 Nm (760 kgf-cm, 55 ft-lb)





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

12. Set timing belt tensioner.
(a) Using a press, slowly press in the push rod using 981-9,807 N (100-1.000 kgf, 200-2,205 lbf) of pressure.





(b) Align the holes of the push rod and housing. pass a 1.5 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.

13. Install timing belt tensioner.





(a) Install the tensioner with the two bolts.

Torque: 26 Nm (270 kgf-cm. 20 ft-lb)





(b) Remove the 1.5 mm hexagon wrench from the tensioner.

14. Check valve timing.
(a) Turn the crankshaft pulley two revolutions from TDC to TDC.





HINT: Always turn the crankshaft clockwise.





(b) Check that each pulley aligns with the timing marks as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.





15. Install engine RH mounting bracket.
Install the mounting bracket with the three bolt.

Torque: 39 Nm (410 kgf-cm, 30 ft-lb)





16. Install No.2 timing belt cover.
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the eight bolts.

HINT: Use the bolts indicated by A, B and C.

17. Install spark plugs.

Torque: 18 Nm (180 kgf-cm, 13 ft-lb)

18. Install PS oil reservoir tank.
19. Install No.2 RH engine mounting bracket and engine moving control rod.





(a) Temporarily install the No.2 RH engine mounting bracket and engine moving control rod with the three bolts in the sequence shown.





(b) Torque the three boils in the sequence shown.

Torque: 64 Nm (650 kgf-cm, 47 ft-lb)





20. Install RH engine mounting stay.
Install the mounting stay with the bolt and nut.

Torque: 31 Nm (320 kgf-cm, 23 ft-lb)

21. Connect connector to ground wire on RH fender apron.
22. Install RH fender apron seal.
23. Install RH front wheel.





24. Install and adjust PS drive belt.
Install the drive belt with the pivot and adjusting bolts.

Drive belt tension:
New belt 150-185 lb
Used belt 115±20 lb





25. Install alternator drive belt.
Adjust the drive belt.

Drive belt tension.
New belt 175±5 lb
Used belt 115±20 lb





26. Install No.2 and No.3 RH engine mounting stays.
(a) Install the No.2 RH engine mounting stay with the bolt and nut.

Bolt
Torque: 75 Nm (760 kgf-cm, 55 ft-lb)

Nut
Torque: 62 Nm (630 kgf-cm, 46 ft-lb)

(b) Install the No.3 RH engine mounting stay with the two bolts.

Torque: 73 Nm (740 kgf-cm, 54 ft-lb)





27. Install coolant reservoir tank.
28. Install washer tank.
(a) Connect the connector and vinyl hose to the washer lank.
(b) Install the washer tank with the three bolts.





29. Install coolant reservoir hose.
Connect the reservoir hose with the bolt.
30. Connect cable to negative terminal of battery.