Installation

TIMING BELT INSTALLATION




1. INSTALL CRANKSHAFT TIMING PULLEY.
(a) Align the timing pulley set key with the key groove of the pulley.
(b) Using SST 09223-46011 and a hammer, tap in the timing pulley, facing the flange side inward.




2. INSTALL NO.1 IDLER PULLEY.
(a) Apply adhesive 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 idler pulley with the pivot bolt.

Torque: 34.5 Nm (350 kgf/cm. 25 ft.lbs.)

(c) Check that the pulley bracket moves smoothly.




3. INSTALL NO.2 IDLER PULLEY.
(a) Install the idler pulley with the bolt.

Torque: 34.5 Nm (350 kgf/cm, 25 ft.lbs.)

(b) Check that the idler pulley moves smoothly.

4. TEMPORARILY INSTALL TIMING BELT.

NOTE: The engine should be cold.

(a) Remove any oil or water on the crankshaft pulley. oil pump pulley, water pump pulley. No.1 idler pulley and No.2 idler pulley, and keep them clean.

NOTE: Only wipe the pulleys; do not use any cleansing agent.




(b) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
(c) Install the timing belt on the crankshaft timing pulley, No.1 idler pulley and No.2 idler pulley.




5. INSTALL TIMING BELT COVER SPACER.
(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.




6. INSTALL TIMING BELT GUIDE.
Install the belt guide. facing the cup side outward.




7. INSTALL NO.1 TIMING BELT COVER.
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the 4 bolts.




8. INSTALL CRANKSHAFT PULLEY.
(a) Align the pulley set key with the key groove of the crankshaft pulley.
(b) Using SST 09223-46011 and a hammer, tap in the crankshaft pulley.




9. INSTALL DRIVE BELT TENSIONER.
Install the belt tensioner with the bolt and 2 nuts.

Torque: 16 Nm (160 kgf/cm, 12 ft.lbs.)

NOTE: Use a bolt 106 mm (4.18 in.) in length.

10. INSTALL GENERATOR.




11. CHECK CRANKSHAFT PULLEY POSITION.
Check that the timing mark of the crankshaft pulley is aligned with the centers of the crankshaft pulley and the idler pulley bolt.




12. INSTALL LH CAMSHAFT TIMING PULLEY.
(a) Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the "L" mark forward.
(c) Using SST 09960-10010 (09962-01000, 09963-01000), install the pulley bolt.

Torque: 108 Nm (1,100 kgf/cm, 80 ft.lbs.)




13. INSTALL RH CAMSHAFT TIMING PULLEY.
(a) Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the ~ mark forward.
(c) Using SST 09960-10010 (09962-01000. 09963-01000), install the pulley bolt.

Torque: 108 Nm (1.100 kgf/cm, 80 ft.lbs.)

14. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY.
(a) Remove any oil or water on the LH camshaft timing pulley, and keep it clean.

NOTE: Only wipe the pulleys: do not use any cleansing agent.




(b) Using SST 09960-10010 (09962-01000, 09963-01000), turn the LH camshaft timing pulley. 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.




(c) Using SST 09960-10010 (09962-01000, 09963-01000), turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and LH camshaft timing pulley.

15. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY.
(a) Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep them clean.

NOTE: Only wipe the pulleys: do not use any cleansing agent.




(b) Using SST 09960-10010(09962-01 000.09963-01000), turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley.




16. 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 pressure.
(b) Align the holes of the push rod and housing, pass a 1.27 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 belt tensioner.




17. INSTALL TIMING BELT TENSIONER.
(a) Temporarily install the belt tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.

Torque: 26 Nm (270 kgf/cm. 19 ft.lbs.)

(c) Using pliers. remove the 1.27 mm hexagon wrench from the belt tensioner.




18. CHECK VALVE TIMING.
(a) Temporarily install the crankshaft pulley bolt.
(b) Slowly turn the crankshaft pulley 2 revolutions front TDC to TDC.

NOTE: Always turn the crankshaft pulley clockwise.




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




19. TIGHTEN CRANKSHAFT PULLEY BOLT.
Using SST 09213-54015 (90119-08216).09330-00021. install the pulley bolt.

Torque: 246 Nm (2.500 kgf/cm. 181 ft.lbs.)




20. INSTALL HYDRAULIC PUMP.
(a) Install the hydraulic pump, solenoid valve connector clamp and crankshaft position sensor wire clamp with the 2 bolts and 2 nuts.

Torque:
12 mm head: 16 Nm (160 kgf/cm, 12 ft.lbs.)
14 mm head: 30 Nm (310 kgf/cm, 22 ft.lbs.)

NOTE: Each bolt length is indicated in the illustration.

Bolt length:
A: 106 mm (4.17 in.)
B: 114 mm (4.49 in.)

(b) Connect the solenoid valve connector.

21. INSTALL A/C COMPRESSOR.
22. INSTALL NO.1 IGNITION COIL.
23. INSTALL DISTRIBUTOR HOUSINGS.




24. INSTALL RH NO.2 TIMING BELT COVER.
(a) Install the 4 gaskets to the timing belt cover.
(b) Install the wire grommet to the timing belt cover.
(c) Fit the timing belt cover, matching it with the fan bracket.
(d) Fit the timing belt cover holes, matching them with the 2 grommets on the distributor.
(e) Install the timing belt cover with the 4 bolts.

Torque: 16 Nm (160 kgf/cm, 12 ft.lbs.) for 12 mm head

NOTE: For 12 mm head: Use bolts 106 mm (4.17 in.) in length.

(f) Install the No.2 camshaft position sensor wire to the wire clamp on the timing belt cover.
(g) Install the wire clamp to the timing belt cover.
(h) Install the sensor connector to the ignition coil bracket.




(i) Install the radiator reservoir outlet pipe to the RH cylinder head and timing belt cover with the 2 bolts.
(j) Connect the outlet hose to the water inlet housing.




25. INSTALL LH NO.2 TIMING BELT COVER.
(a) Install the 2 gaskets to the timing belt cover.
(b) Run the No.1 camshaft position sensor wire through the timing belt cover hole.
(c) Fit the timing belt cover, matching it with the fan bracket.
(d) Fit the timing belt cover holes, matching them with the 2 grommets on the distributor.
(e) Install the timing belt cover and connector bracket with the 3 bolts.
(f) Install the wire grommet to the timing belt cover.
(g) Install the sensor connector to the connector bracket.
(h) Connect the sensor connector.
(i) Install the sensor wire to the wire clamp on the timing belt cover.
(j) Install the engine wire to the 2 wire clamps on the timing belt cover.




26. INSTALL DRIVE BELT IDLER PULLEY.
Install the idler pulley and cover plate with the bolt.

Torque: 37 Nm (380 kgf/cm. 27 ft.lbs.)




27. INSTALL RH NO.3 TIMING BELT COVER.
(a) Install the 3 gaskets to the timing belt cover.
(b) Fit the portion A of the timing belt cover, matching with the lower high-tension cord cover.
(c) Install the timing belt cover with the 4 bolts.




28. INSTALL LH NO.3 TIMING BELT COVER.
(a) Install the 3 gaskets to the timing belt cover.
(b) Install the cord grommet to the high-tension cord (from the LH ignition coil).
(c) Install the cord grommet to the timing belt cover.
(d) Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
(e) Install the timing belt cover with the 4 bolts.

29. INSTALL RADIATOR ASSEMBLY.
30. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY.
31. INSTALL V-BANK COVER.
32. FILL WITH ENGINE COOLANT.
33. START ENGINE AND CHECK FOR LEAKS.
34. RECHECK ENGINE COOLANT LEVEL.
35. INSTALL BATTERY CLAMP COVER.
36. INSTALL ENGINE UNDER COVER.