Installation

INSTALLATION




Part 1




Part 2

Service Points of Installation

NOTE: Step numbers refer to procedure shown in images above.

28. INSTALLATION OF FLANGE




- Install the flange in correct direction as shown.

Caution: Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken timing belt could result.

27. INSTALLATION OF CRANKSHAFT SPROCKET

- Install the crankshaft sprocket in the correct direction as shown.

Caution: Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken timing belt could result.

2. INSTALLATION OF CRANKSHAFT PULLEY




(1) Using the special tool and a disused drive belt, stop the rotation of the crankshaft pulley.




(2) Tighten the crankshaft sprocket bolt to the specified torque.

23. INSTALLATION OF CAMSHAFT SPROCKETS




- Using a wrench, hold the camshaft at its hexagon between the No. 2 and No. 3 journals and tighten the bolt to specification.




Caution: Locking the camshaft sprocket with a tool damages the sprocket.

18. INSTALLATION OF AUTO TENSIONER

(1) If the auto tensioner rod is in its fully extended position, reset it as follows:




(a) Keep the auto tensioner level and, in that position, clamp it in the vise with soft jaws.




NOTE: If the plug at the bottom of the auto tensioner protrudes, apply a plain washer as illustrated to prevent the plug from being in direct contact with the vise.




(b) Push in the rod slowly with the vise until the set hole (A) in the rod is aligned with that (B) in the cylinder.




(c) Insert a wire [1.4 mm (.055 in.) in diameter] into the set holes.
(d) Unclamp the auto tensioner from the vise.

(2) Install the auto tensioner.

Caution: Leave the wire installed in the auto tensioner.

20. INSTALLATION OF TENSIONER PULLEY

(1) Install the tensioner pulley onto the tensioner arm.




(2) Locate the pinhole in the tensioner pulley shaft to the left of the center bolt. Then, tighten the center bolt finger tight.

Caution: Leave the wire installed in the auto tensioner.

19. INSTALLATION OF TIMING BELT




(1) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate one tooth in the counter-clockwise direction. This should be taken into account when installing the timing belt on the sprockets.




NOTE: The same camshaft sprocket is used for the intake and exhaust camshafts and is provided with two timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the one on the left with the dowel pin hole on top.




(2) Align the crankshaft sprocket timing marks.
(3) Align the oil pump sprocket timing marks.
(4) Install the timing belt around sprockets as follows:




(a) Install the timing belt around the tensioner pulley and crankshaft sprocket and secure the timing belt onto the tensioner pulley with your left hand.
(b) Pulling the belt with your right hand, install it around the oil pump sprocket.
(c) Install the belt around the idler pulley.
(d) Install it around the intake camshaft sprocket.
(e) Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder head top surface (see illustration in step 1). Then, pulling the belt with both hands, install it around the exhaust camshaft sprocket.
(f) Gently raise the tensioner pulley as shown by the arrow, so that the belt does not sag, and temporarily tighten the center bolt.

10. INSTALLATION OF TIMING BELT LOWER COVER / 9. TIMING BELT UPPER COVER




- The dimensions of the installation bolts for the timing covers differ according to the installation location, so be sure not to install the bolts in the incorrect locations.

Adjustment of Timing Belt Tension

(1) After turning the crankshaft 1/4 turn counterclockwise, turn it clockwise to move the No.1 cylinder to top dead center.




(2) Loosen the center bolt, and then, as shown in the illustration, attach the special tool and a torque wrench and apply a torque of 2.6 - 2.8 Nm (1.88 - 2.03 ft.lbs.). If the body interferes with the special tool and the torque wrench, use a jack to slightly raise the engine assembly.

NOTE: Use a torque wrench that is capable of measurement within a range of 0 - 3 Nm (0 - 2.2 ft.lbs.).




(3) Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification.
(4) Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At that point, screw the special tool some more and then remove the set wire attached to the auto tensioner.
(5) Remove the special tool.




(6) Rotate the crankshaft two complete turns clockwise and leave it as is for about 15 minutes. Then, measure the auto tensioner protrusion "A" (distance between the tensioner arm and auto tensioner body) to ensure that it is up to specification.

Standard value: 3.8 - 4.5 mm (0.15 - 0.18 in.)

If it is out of specification, repeat steps (1) through (6) until the specified value is obtained

(7) If the clearance "A" between the tensioner arm and the auto tensioner body cannot be measured (when the engine is mounted on the vehicle, for example, the following alternative method may be used.




(1) Screw in the special tool until its end makes contact with the tensioner arm.




(2) Starting with that position, screw in the special tool some more to retract the auto tensioner push rod while counting the number of turns of the tool makes until the tensioner arm is brought into contact with the auto tensioner body. Make sure that the number of turns the special tool makes conforms with the standard value.

Standard value: 2.5 - 3 turns




(8) Install the rubber plug to the timing belt rear cover.