Installation
CAUTION: INTERFERENCE ENGINE
When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.
INSTALLATION
Automatic Belt Tension Adjuster Assembly and Belt Idler
1. Preparation for installation of automatic belt 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 lbs.).
^ 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 lbs.).
^ Press the adjuster rod as far as the end surface of the cylinder. 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 lbs.) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
3) With a 2 mm (0.08 inch) diameter stopper pin or a 2 mm (0.08 inch) (nominal) diameter hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
2. Install automatic belt tension adjuster assembly.
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
3. Install belt idler (No. 1).
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
Timing Belt
1. Installation of timing belt
1) Turn camshaft sprocket No. 2 using ST1, and turn camshaft sprocket No. 1 using ST2 so that their alignment marks come to top positions.
ST1 499207100 CAMSHAFT SPROCKET WRENCH
2) While aligning alignment mark on timing belt with marks on sprockets, position timing belt properly.
CAUTION: Ensure belt's rotating direction is correct.
2. Install belt idler No. 1.
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
3. Install belt idler (No. 2).
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
4. After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper pin from belt tensioner adjuster.
CAUTION: After properly installing timing belt, remove rocker cover and ensure that the valve lash adjuster contains no air.
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 by using thickness gauge.
Clearance: 1.0 ±0.5 mm (0.039 ±0.020 inch)
3) Tighten remaining bolts.
Tightening torque: 9.8 Nm (1.0 kgf-m, 7.2 ft. lbs.)
Crankshaft Pulley and Belt Cover
1. Install front belt cover.
Tightening Torque: 5 Nm (0.5kg-m, 3.6 ft. lbs.)
2. Install LH belt cover.
Tightening Torque: 5 Nm (0.5kg-m, 3.6 ft. lbs.)
3. Install crankshaft pulley.
4. Install pulley bolt
To lock crankshaft, use ST 499977100 Crankshaft Pulley Wrench.
a. Clean the crankshaft pulley thread using an air gun.
b. Apply engine oil to the crankshaft pulley bolt seat and thread.
c. Tighten the bolt temporarily with tightening torque of 44 Nm (4.5kg-m, 33 ft.lbs.)
d. tighten the crankshaft pulley bolt.
Tightening torque: 177 Nm (18.0 kg-m, 130.2 ft. lbs.)
e. Confirm that the tightening angle of the crankshaft pulley bolt is 65° or more, if not replace crankshaft pulley bolt.
Caution: Conduct the tightening procedures by confirming the turning angle of the crankshaft pulley bolt referring to the gauge indicated on the belt cover.
5. Install A/C belt tensioner. (With A/C model)
6. Install A/C belt. (With A/C model)