Installation

TIMING BELT INSTALLATION




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.

NOTE: Do not scratch the sensor part of the crankshaft timing pulley.




(c) Install the timing belt plate with the bolt.

Torque: 7.8 Nm (80 kgf/cm, 69 in.lbs.)




2. INSTALL IDLER PULLEY.
(a) Apply adhesive to 2 or 3 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.lbs.)

(c) Check that the pulley bracket moves smoothly.

3. TEMPORARILY INSTALL TIMING BELT.

NOTE: 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.

NOTE: When re-using timing belt. Align the match marks 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 gasket to the timing belt cover.
(b) Install the timing belt cover with the 5 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 09213-70010,09330-00021, install and torque the bolt.

Torque: 324 Nm (3,300 kgf/cm, 239 ft.lbs.)




7. INSTALL CAMSHAFT TIMING PULLEYS.
(a) Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley.
(b) Temporarily install the timing pulley bolt.




(c) Using SST 09960-10010 (09962-01000, 09963-01000) to hold the pulley, torque the pulley bolt.

Torque: 79 Nm (810 kgf/cm, 59 ft.lbs.)




8. SET NO.1 CYLINDER TO TDC/COMPRESSION.
(a) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No.1 timing belt cover.

NOTE: Always turn the crankshaft clockwise.




(b) Using SST 09960-10010 (09962-01000, 09963-01000), align the timing marks of the camshaft timing pulleys and No.4 timing belt cover.

9. INSTALL TIMING BELT.




NOTE: 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 981-9,807 N (100-1,000 kgf, 220-2,205 lbs.) of force.
(b) Align the holes of the push rod and housing, pass a 1.5 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 2 bolts.
(b) Alternately tighten the 2 bolts.

Torque: 26 Nm (270 kgf/cm, 20 ft.lbs.)




(c) Remove the 1.5 mm hexagon wrench from the tensioner with pliers.

12. CHECK VALVE TIMING.
(a) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

NOTE: 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.




13. INSTALL DRIVE BELT TENSIONER.

Torque: 21 Nm (210 kgf/cm, 15 ft.lbs.)

NOTE: Be careful not to drop the bolts inside the timing belt cover.

14. INSTALL NO.2 TIMING BELT COVER.
15. INSTALL NO.3 TIMING BELT COVER.
16. INSTALL PS PUMP FRONT BRACKET AND PUMP PULLEY.
(a) Temporarily install the pump front bracket with the 2 bolts (A).
(b) Install the plate washer and bolt (B), and tighten the 2 bolts (A).

Torque:
58 Nm (590 kgf/cm, 43 ft.lbs.) for A
52 Nm (530 kgf/cm, 38 ft.lbs.) for B




(c) Temporarily install the pump pulley with the nut.
(d) Using SST 09960-10010 (09962-01000, 09963-01000), tighten the pulley nut.

Torque: 43 Nm (440 kgf/cm, 32 ft.lbs.)

17. INSTALL RADIATOR ASSEMBLY.




18. INSTALL WATER PUMP PULLEY, FAN, FLUID COUPLING ASSEMBLY AND DRIVE BELT.
(a) Align the matchmarks, and install the water pump pulley, the fan and fluid coupling assembly with the 4 nuts.
(b) Install the drive belt by turning the drive belt tensioner clockwise.
(c) Stretch the belt tight and tighten the 4 nuts.

Torque: 16 Nm (165 kgf/cm, 12 ft.lbs.)

19. INSTALL AIR CLEANER DUCT.
20. FILL ENGINE WITH COOLANT.
21. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL.
22. START ENGINE CHECK FOR LEAKS.
23. INSTALL ENGINE UNDER COVER.
24. ROAD TEST.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
25. RECHECK ENGINE COOLANT LEVEL.