Installation
TIMING BELT
INSTALLATION
SPROCKET
1) Install right-hand belt cover No.2.
2) Install left-hand belt cover No.2.
3) Install tensioner bracket
4) Install crankshaft sprocket.
5) Install right-hand exhaust camshaft sprocket. To lock camshaft, use ST.
6) Install right-hand intake camshaft sprocket using ST.
7) Install left-hand exhaust camshaft sprocket using ST.
8) Install left-hand intake camshaft sprocket using ST.
ST 499207300 CAMSHAFT SPROCKET WRENCH
2. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic be~ tension adjuster assembly:
CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically. Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kg, 66 lb). Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder.
WARNING: DO NOT PRESS THE ADJUSTER ROD INTO THE CYLINDER. DOING SO MAY DAMAGE THE CYLINDER. DO NOT RELEASE PRESS PRESSURE UNTIL STOPPER PIN IS COMPLETELY INSERTED.
(1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool
(2) Slowly move the adjuster rod down with a pressure of 294 N (30 kg, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
2) Install Automatic belt tension adjuster assembly.
3) Install belt idler No.2.
4) Install belt idler.
TIMING BELT
1) Crankshaft and camshaft sprocket alignment.
(1) Align mark on crankshaft sprocket with mark on the oil pump cover at cylinder block.
(2) Align single line mark on right-hand exhaust camshaft sprocket with notch on belt cover.
(3) Align single line mark on right-hand exhaust camshaft sprocket with notch on belt cover. (Make sure double lines on intake camshaft and exhaust camshaft sprockets are aligned.)
(4) Align single line mark on left-hand exhaust camshaft sprocket with notch on belt cover by turning sprocket counter-clockwise (as viewed from front of engine).
(5) Align single tine mark on left-hand intake camshaft sprocket with notch on belt cover by turning sprocket clockwise (as viewed from front of engine). Ensure double tines on intake and exhaust camshaft sprockets are aligned.
(6) Ensure camshaft and crankshaft sprockets are positioned as shown.
WARNING: INTAKE AND EXHAUST CAMSHAFTS FOR THIS DOHC ENGINE CAN BE INDEPENDENTLY ROTATED WITH TIMING BELTS REMOVED. AS CAN BE SEEN FROM THE FIGURE, IF INTAKE AND EXHAUST VALVES ARE LIFTED SIMULTANEOUSLY, THEIR HEADS WILL INTERFERE WITH EACH OTHER, RESULTING IN BENT VALVES.
- When timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push intake and exhaust valves down. (Under this condition, all valves remain un-lifted.)
- When camshafts are rotated to install timing belts, #2 intake and #4 exhaust cam of left-hand camshafts are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Right-side camshafts are held so that their cams do not push valves down.
- Left-hand camshafts must be rotated from the "zero-lift" position to the position where timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads.
WARNING DO NOT ALLOW CAMSHAFTS TO ROTATE IN THE DIRECTION SHOWN IN THE FIGURE AS THIS CAUSES BOTH INTAKE AND EXHAUST VALVES TO LIFT SIMULTANEOUSLY, RESULTING IN INTERFERENCE WITH THEIR HEADS.
2) Installation of timing belt
Align alignment mark on timing belt with marks on sprockets in the numerical order shown in figure. While aligning marks, position timing belt properly.
WARNING: DISENGAGEMENT OF MORE THAN THREE TIMING BELT TEETH MAY RESULT IN INTERFERENCE BETWEEN THE VALVE AND PISTON. ENSURE BELT'S ROTATING DIRECTION IS CORRECT.
3) Install belt idler.
WARNING: MAKE SURE THAT THE MARKS ON TIMING BELT AND SPROCKETS ARE ALIGNED.
4) After ensuring that the marks on timing belt and sprockets are aligned, remove stopper pin from tensioner adjuster.
5) Install timing belt guide. (MT vehicles only)
(1) Temporarily tighten remaining bolts.
(2) Check and adjust clearance between timing belt and timing belt guide.
Clearance: 1.0+0.5 mm (0.03-0.020 in)
4. CRANKSHAFT PULLEY AND BELT COVER
(3) Tighten remaining bolts.
1) Install front belt cover.
2) Install right-hand belt cover
3) Install left-hand belt cover
4) Install crankshaft pulley.
5) Tighten pulley bolt by using ST.
ST 499977100 CRANKSHAFT PULLEY WRENCH
6) Install V-belt, air conditioning compressor drive belt tensioner and V-belt cover.
CAUTION: After installing V-belt, check and adjust V-belt tension.