Timing Belt Installation

TIMING BELT INSTALLATION





1. Install crankshaft timing pulley.
(a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley.
(b) Slide on the timing pulley, facing the flange side inward.





2. Install No.1 idler pulley.
(a) Using a 10 mm hexagon wrench, install the No.1 idler pulley with the plate washer and bolt.

Torque: 35 N.m (350 kgf.cm, 26 ft.lbf)

(b) Check that the pulley bracket moves smoothly.
3. Install No.2 idler pulley.
(a) Install the No.2 idler pulley with the bolt.

Torque: 40 N.m (400 kgf.cm, 30 ft.lbf)

(b) Check that the No.2 idler pulley moves smoothly.





4. Install LH camshaft timing pulley.
(a) Face the flange side of the timing pulley outward.
(b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley.
(c) Using SST 09960-10010 (09962-01000, 09963-01000), install the pulley bolt.

Torque: 110 N.m (1,100 kgf.cm, 81 ft.lbf)





5. Install RH camshaft timing pulley.
(a) Face the flange side of the timing pulley outward.
(b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley.
(c) Using SST 09960-10010 (09962-01000, 09963-01000), install the pulley bolt.

Torque: 110 N.m (1,100 kgf.cm, 81 ft.lbf)

6. Set No.1 cylinder to TDC/Compression.





(a) Crankshaft Timing Pulley Position:
- Temporarily install the crankshaft pulley bolt to the crankshaft.
- Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body.





(b) Camshaft Timing Pulley Positions:
Using SST 09960-10010 (09962-01000, 09963-01000), turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover.

7. Install timing belt.

NOTICE: The engine should be cold.

(a) Remove any oil or water on the pulleys, and keep them clean.

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

(b) Face the front mark on the timing belt forward.
(c) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.





(d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
(e) Install the timing belt in this order:
(1) LH camshaft timing pulley
(2) No.2 idler pulley
(3) RH camshaft timing pulley
(4) Water pump pulley
(5) Crankshaft timing pulley
(6) No.1 idler pulley
8. Set timing belt tensioner.
(a) Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 200 - 2,205 lbf) 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 tensioner.





9. Install timing belt tensioner.
(a) Temporarily install the tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

(c) Remove the 1.27 mm hexagon wrench from the tensioner.
10. Check valve timing.
(a) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body.

NOTICE: Always turn the crankshaft clockwise.





(b) Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
(c) Remove the crankshaft pulley bolt.





11. Install timing belt guide, facing the cup side outward.





12. Install No.1 timing belt cover and starter wire bracket.
(a) Check that the timing belt cover gaskets have cracks or peeling, etc.
If the gasket does have cracks or peeling. etc. replace it using following steps.
- Using a screwdriver and gasket scraper, remove all the old gasket material.
- Thoroughly clean all components to remove all the loose material.

No. 1 Cover (Back):

No. 1 Cover (Front):

- Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration.
(b) Install the timing belt cover with the 4 bolts.

Torque: 9 N.m (90 kgf.cm, 80 in.lbf)

(c) Install the starter wire bracket with the 2 bolts.
13. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, and slide the pulley.
(b) Using SST 09213-54015 (90119-08216), 09330-00021, install and torque the bolt.

Torque: 250 N.m (2,500 kgf.cm, 184 ft.lbf)





14. Install fan bracket.
(a) Install the fan bracket with the bolt and nut.
(b) Install the PS pump adjusting strut with the nut.





15. Install No.2 timing belt cover.
(a) Check that the timing belt cover gasket has no cracks or peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using following steps.
- Using a screwdriver and gasket scraper, remove all the old gasket material.
- Thoroughly clean all components to remove all the loose material.
- Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration.
(b) Install the belt cover with the 6 bolts.

Torque: 9 N.m (90 kgf.cm, 80 in.lbf)

(c) Connect the 4 high-tension cord clamps and camshaft position sensor connector to the No.2 timing belt cover.

16. Install oil dipstick and guide.
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Install the oil dipstick and guide to the cylinder block.
(d) Install the bolt to the generator bracket.

Torque: 8 N.m (80 kgf.cm, 71 in.lbf)

17. On vehicles with A/C, install A/C compressor bracket.

Torque: 47 N.m (479 kgf.cm, 35 ft.lbf)

18. Temporarily install fan with fluid coupling and fan pulleys.
19. Install No.2 fan shroud.
20. Install and adjust drive belt for generator.
21. Tighten fan with fluid coupling and fan pulleys.

Torque: 5.4 N.m (54 kgf.cm, 48 in.lbf)

22. On vehicles with A/C, connect A/C compressor to engine.
(a) Install the A/C compressor with the 4 bolts.

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)

(b) Install the drive belt.
(c) Connect the A/C compressor connector.
23. Connect PS pump to engine.
(a) Temporarily install the PS pump with the bolt and nut.
(b) Install the drive belt.
(c) Tighten the bolt and nut.

Torque: 43 N.m (440 kgf.cm, 31 ft.lbf)

(d) Install the PS pressure tube clamp with the bolt.
(e) Connect the 2 PS air hoses to the air intake chamber and resonator.
24. Connect upper radiator hose.
25. Fill engine with coolant.
26. Start engine check for leaks.
27. Install engine under cover.
28. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
29. Recheck engine coolant level.