Timing Belt Installation

INSTALLATION





1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft. and slide on the pulley.
(b) Using SST. install the pulley nut.
SST 09960-10010 (09962-01000. 09963-00500)

Torque: 24 N.m (245 kgf.cm. 18 ft.lbf)





2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the flange side inward.





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

Torque: 42 N.m (425 kgf.cm. 31 ft.lbf)

HINT: Use the 35 mm (1.38 in.) long bolt.

(b) Check that the idler pulley moves smoothly.

4. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING





(a) Align the bracket pin hole with the pivot pin.
(b) Install the pulley with the bolt. Do not tighten the bolt yet.

HINT: Use the 42 mm (1.65 in.) long bolt.

(c) Install the tension spring.





(d) Pry the pulley toward the left as far as it will go and tighten the bolt.
(e) Check that the idler pulley moves smoothly.

5. TEMPORARILY INSTALL TIMING BELT

NOTICE: The engine should be cold.





(a) Using the crankshaft pulley bolt. turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body.





(b) 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.
(c) Install the timing belt on the crankshaft timing pulley, oil pump pulley, No.1 idler pulley, water pump pulley and No.2 idler pulley.

HINT (When re-using timing belt): Align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.





6. INSTALL TIMING BELT GUIDE
Install the 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 pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-54015 (09214-00030). 09330 - 00021

Torque: 108 N.m (1,100 kgf.cm, 80 ft.lbf)

9. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the timing pulley.





(b) Using SST, install the pulley bolt.
SST 09249-03010.09960-10010 (09962-01000. 09963-01000)

Torque:
54 N.m (550 kgf.cm. 40 ft.lbf)
37 N.m (380 kgf.cm, 27 ft.lbf) for SST

HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).





10. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley. and align its groove with timing mark "0" of the No.1 timing belt cover.
(b) Using SST, turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap.
SST 09960-10010 (09962-01000.09963 - 01000)

11. INSTALL TIMING BELT





HINT (When re-using timing belt):
- Check that the matchmarks on the timing belt matches the end of the No.1 timing belt cover.
If the matchmarks do not align, shift the meshing of the timing belt and crankshaft timing pulley until they align.





- Align the matchmarks of the timing belt and camshaft timing pulley.

(a) Remove any oil or water on the camshaft timing pulley, and keep it clean.
(b) Install the timing belt, and checking the tension between the crankshaft timing pulley and camshaft timing pulley.

12. CHECK VALVE TIMING





(a) Loosen the No.1 idler pulley bolt 1/2 turn.
(b) Slowly turn the crankshaft pulley 2 revolutions TDC to TDC.

NOTICE: 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.





(d) Slowly turn the crankshaft pulley 1 and 7/8 revolutions and align its groove with the mark at 45° BTDC (for No.1 cylinder) of the No.1 timing belt cover.

NOTICE: Always turn the crankshaft pulley clockwise.

(e) Torque the mounting bolt of the No.1 idler pulley.

Torque: 42 N.m (425 kgf.cm. 31 ft.lbf)





13. INSTALL NO.2 TIMING BELT COVER
(a) Install the gasket to the No.1 timing belt cover.
(b) Disconnect the engine wire protector between the No. 3 timing belt cover and cylinder head cover.
(c) Install the belt cover with the 5 bolts.
(d) Install the 2 clamps of the engine wire protector to each bolt.

14. INSTALL SPARK PLUGS

Torque: 18 N.m (180 kgf.cm. 13 ft.lbf)





15. INSTALL RH ENGINE MOUNTING BRACKET
(a) Place the mounting bracket in position.

HINT: Raise the engine as far as it will go, and place the mounting bracket in position.

(b) Install the mounting bracket with the 4 bolts.

Torque: 61 N.m (820 kgf.cm. 45 ft.lbf)





16. INSTALL RH ENGINE MOUNTING INSULATOR
Install the mounting insulator with the through bolt and 2 nuts.

Torque:
Nut: 52 N.m (530 kgf.cm. 38 ft.lbf)
Through bolt: 78 N.m (800 kgf.cm. 58 ft.lbf)





17. INSTALL RH ENGINE MOUNTING STAY

Torque: 73 N.m (740 kgf.cm. 54 ft.lbf)

18. INSTALL RH REAR WHEEL
19. INSTALL GENERATOR DRIVE BELT
20. INSTALL A/C DRIVE BELT
21. CONNECT GROUND STRAP CONNECTOR
22. CONNECT BRAKE BOOSTER HOSE

23. W/ Cruise Control System: INSTALL CRUISE CONTROL ACTUATOR AND ACCELERATOR LINKAGE
24. INSTALL RH ENGINE HOOD SIDE PANEL
25. INSTALL ENGINE UNDER COVERS