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

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 N.m (350 kg.cm, 25 ft.lb)

(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.

HINT: (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 ps pump front bracket
(a) Install the pump front bracket with the 2 bolts.

Torque: 58 N.m (590 kg cm, 43 ft.lb)

(b) Install the plate washer and bolt to the oil pump.

Torque: 52 N.m (530 kg cm, 38 ft.Ib)

7. 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 09213-70010,09330-00021

Torque: 324 N.m (3,300 kg cm, 239 ft.lb)

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

Torque: 79 N.m (810 kg cm, 59 ft.lb)

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

10. 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.

11. Set timing belt tensioner
(a) Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kg cm, 220 - 2,205 lb) 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.

12. Install timing belt tensioner

(a) Temporarily install the tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.

Torque: 26 N.m (270 kg cm, 20 ft.lb)

(a) 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 ane reinstall it.

14. Install drive belt tensioner
Install the tensioner with the 3 bolts.

Torque: 21 N.m (210 kg cm, 15 ft.lb)

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

15. INSTALL NO.2 AND NO.3 TIMING BELT COVERS
(a) Install the gasket on the liming belt cover.

(b) Using a 5 mm hexagon wrench install the belt covers with the 9 bolts.
(c) Install the oil filler cap.

16. Install radiator
(a) Place the radiator on the body bracket.

(b) Install the upper radiator support with the 2 bolts and screw. Install the 2 upper radiator supports.

(c) Connect the following hoses:
(1) Reservoir hose to radiator
(2) Upper radiator hose to water iniet
(3) Lower radiator hose to water outlet
(4) A/T: Oil cooler hoses to radiator

17. Install water pump pulley, fan with fluid coupling and drive belt

(a) Align the matchmarks, and install the water pump pulley and fan with fluid coupling with the 4 nuts.

(b) Install the drive belt by turning the drive belt tensioner clockwise.

18. Install battery tray and battery
19. Fill with engine coolant

Coolant capacity (w/ Heater):
M/T: 8.5 liter: (9.0 US qts, 7.5 Imp. qts)
A/T: 8.4 liter: (8.9 US qts, 7.4 Imp. qts)

20. Start engine and check for leaks
21. A/T: Check automatic transmission fluid level
22. Check ignition timing
23. Install engine under cover
24. Perform road test
Check for abnormal noises, shock, slippage, correct shift points and smooth operation.

25. Recheck engine coolant level