Installation
COMPONENTS
INSTALLATION OF TIMING BELT
1. Install crankshaft timing pulley.
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley facing the flange side inward.
2. Install idler pulley.
(a) Apply adhesive to two or three threads of the pivot bolt.
Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer and pulley with the pivot 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) Use the crankshaft pulley bolt to turn the crankshaft and align the timing marks on the crankshaft timing pulley and on the oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.
(c) Install the timing belt on the crankshaft timing pulley and idler pulley.
HINT (When re-using timing belt): Align the matchmarks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.
4. Install timing belt guide.
Install the guide, facing the cup side outward.
5. Install No.1 timing belt cover.
(a) Install the two gaskets to the timing belt cover.
(b) Install the timing belt cover with the five bolts.
6. 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 and torque the bolt. SST 09213-54015 (09651-60855) and 09330-00021
Torque: 324 Nm (3,300 kgf-cm, 239 ft-lb)
7. Install camshaft timing pulleys.
(a) Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley.
(b) Using SST to hold the pulley, torque the pulley bolt. SST 09278-54012
Torque: 79 Nm (810 kgf-cm, 59 ft-lb)
8. Set No.1 cylinder to TDC/Compression.
(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
(b) Turn the camshaft, and align the timing marks of the camshaft timing pulleys and No.4 timing belt cover. SST 09278-54012
9. Install timing belt.
HINT (When re-using timing belt): Align the matchmarks of the timing belt and camshaft timing pulleys.
(a) Remove any oil or water on the camshaft timing pulley, and keep it clean.
(b) Install the timing belt, checking the tension between the crankshaft timing pulley and exhaust camshaft timing pulley.
10. Set timing belt tensioner.
(a) Using a press, slowly press in the push rod using 981-9,807N (100-1,000 kgf, 220 - 2,205 lb) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.50 mm hexagon wrench through the holes to keep the push rod retracted.
(c) Release the press.
(d) Install the dust boot onto the tensioner.
11. Install timing belt tensioner.
(a) Temporarily install the tensioner with the two bolts.
(b) Alternately tighten the two bolts.
Torque: 26 Nm (270 kgf-cm 20 ft-lb)
(c) Remove the 1.50 mm hexagon wrench from the tensioner with pliers.
12. Check valve timing.
(a) Turn the crankshaft pulley two revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as shown in the figure
If the marks do not align, remove the timing belt and reinstall it.
13. Install drive belt tensioner.
Install the tensioner with the three bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft-lb)
NOTICE: Be careful not to drop the bolts inside the timing belt cover.
14. Install No.2 and No.3 timing belt covers.
(a) Install the gasket on the timing belt cover.
(b) Using a 5 mm hexagon wrench, install the belt covers with the nine bolts.
(c) Install the oil filler cap.
15. Install radiator and water pump pulley.
16. Fill engine with coolant.
Capacity (w/ Heater):
M/T 8.5 liters (9.0 US qts, 7.5 Imp. qts)
A/T 8.4 liters (8.9 US qts, 7.4 Imp. qts)
17. (A/T)
Check automatic transmission fluid level.
NOTICE: Do not overfill.
18. Start engine and check for leaks.
19. Check ignition timing.
Ignition timing: 10° BTDC @ idle
(w/ Terminals TE1 and E1 connected)
20. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
21. Recheck engine coolant level.