Installation

1. Installation of camshaft timing belt pulley.
(a) Assemble the camshaft timing belt pulley by aligning its key groove with the woodruff key of the camshaft.

NOTE:
- Remove any oil or water from the camshaft timing belt pulley. Keep the pulley clean.
- If the camshaft timing belt pulley can not be inserted by hand, for easier insertion, lightly tap it from the front using a plastic hammer.

During the installation, care must be exercised to ensure that the woodruff key is not displaced.

(b) Tighten the attaching bolt of the camshaft timing belt pulley.
During this operation, prevent the pulley rotation by inserting an iron rod into the hole of the pulley, utilizing the rib at the cylinder head side.

Tightening Torque:
3.0 - 4.5 kg-m (21.7 - 32.5 ft-lb, 29.4 - 44.1 Nm)

Crank Pulley:

2. Installation of crankshaft timing belt pulley flange. Install the crankshaft timing belt pulley flange with its recessed side facing toward the cylinder block.

NOTE: Remove any oil or water from the pulley flange. Keep the pulley flange clean.

Crank Pulley:

3. Installation of crankshaft timing belt pulley.
Assemble the crankshaft timing belt pulley by aligning its key groove with the woodruff key of the crankshaft.

NOTE: Remove any oil or water from the idler pulley. Keep the idler pulley clean.

Tensioner Spring And Idler:

4. Installation of idler pulley and return spring.
(a) Temporarily install the timing belt idler pulley with the mount bolt.
(b) Install the tension spring.
(c) With the idler pulley fully pushed to the left, temporarily tighten it.

NOTE: Remove any oil or water from the idler pulley. Keep the idler pulley clean.

5. Timing belt installation.
(a) Ensure that the mating mark of the crankshaft timing belt pulley is aligned with the mating mark on the cylinder head.

^ If the timing marks are not aligned with each other, align them.
However, keep rotation of the timing belt pulley at a minimum so that the piston may not interfere with the valve.

Turning Crank:

^ Turn the crankshaft by applying a stubby screwdriver to the timing gear.

(b) Ensure that the mating mark of the camshaft timing belt pulley is aligned with the mating mark on the balance shaft gear cover.

^ If the timing marks are not aligned with each other, align them.
However, keep rotation of the timing belt pulley at a minimum so that the piston may not interfere with the valve.

Belt Direction:

(c) Install the timing belt.

NOTE: When the timing belt is reused, install the timing belt in such a way that the direction of the arrow put during the removal may match with the engine rotation direction.

Timing Marks:

^ When a new belt is installed, align the line mark on the belt back side with the corresponding mating mark on each pulley.

Pulley And Bolt:

(d) Loosen the attaching bolt of the idler pulley. Apply tension to the timing belt by means of the tension spring. Then, temporarily tighten the attaching bolt again.

Crank Bolt:

(e) Screw in the crankshaft pulley bolt to the crankshaft. Turn the crankshaft two turns and stop it when the piston No.1 reaches the top dead center. During this operation, never turn the crankshaft in reverse.
If the crankshaft is reversed, turn the crankshaft two turns again. Then, stop the crankshaft when the piston No.1 reaches the top dead center.

NOTE: When the "F" mark comes just at the top position, the piston No.1 is also at the top dead center.

Idler Pulley And Bolt:

(f) Loosen the attaching bolt of the idler pulley. Apply tension to the timing belt by means of the tension spring. Tighten the attaching bolt again.

Tightening Torque:
3.0 - 4.5 kg-m (24.6 - 32.5 ft-lb., 33.3 - 44.1 Nm)

Timing Marks:

(g) Ensure that the mating marks on the crankshaft and camshaft timing belt pulleys are aligned with the corresponding mating marks on the balance shaft gear cover and cylinder head.
If they are not aligned, remove the timing belt again and perform the operations starting from Step (1).

Crank Pulley Flange:

6. Installation of crankshaft timing belt pulley flange. Install the crankshaft timing belt pulley flange with the protruding side facing toward the crankshaft timing belt pulley.

Lower Cover:

7. Install the timing belt lower cover with its gasket.

Tightening Torque:
0.2 - 0.4 kg-m (1.4 - 2.9 ft-lb., 2.0 - 3.9 Nm)

Upper Cover:

8. Install the timing belt upper cover with the gasket interposed.

Tightening Torque:
0.2 - 0.4 kg-m (1.4 - 2.9 ft-lb, 2.0 - 3.9 Nm)

Crank Pulley:

9. Installation of crankshaft pulley.
(a) Insert the crankshaft pulley with the key groove on the crankshaft pulley aligned with the crankshaft key.
(b) Tighten the crankshaft pulley bolt.

Tightening Torque:
9.0 - 10.0 kg-m (65.1 - 72.0 ft-lb., 88.3 - 98.0 Nm)

Holding Ring Gear:

NOTE:
- When installing the crankshaft pulley bolt, both the bolt and bolt hole of the crankshaft pulley should be dry.
- During the bolt tightening, prevent the ring gear from turning, using a screwdriver.

Water Pump Pulley:

10. Installation of water pump pulley.
Temporarily tighten the attaching bolt of the water pump pulley.
Tighten the attaching bolt, while preventing the ring gear from turning, using a flat screwdriver.

Tightening Torque:
0.6 - 0.9 kg-m (4.3 - 6.5 ft-lb, 5.9 - 8.8 Nm)

Front Mounting Bracket:

11. Install the front mounting bracket to the cylinder head.

Tightening Torque:
M12 Bolt 5.0 - 7.0 kg-m (36.2 - 50.6 ft-lb., 49.0 - 68.6 Nm)
M10 Bolt 3.0 - 4.5 kg-m (21.7 - 32.5 ft-lb., 29.4 - 44.1 Nm)

12. Tighten the front mounting bracket together with the front mounting by means of the attaching nuts.

Tightening Torque:
4.0 - 5.5 kg-m (28.9 - 39.8 ft-lb., 39.2 - 53.9 Nm)

Front Engine Cover:

13. Install the right front engine under cover.
14. Remove the garage jack.

15. Installation of alternator drive belt.

Alternator Belt Alignment:

(a) Install the alternator drive belt correctly.

Tightening Alternator Belt:

(b) Using a T-shaped wrench or the like, apply tension to the drive belt and temporarily tighten the lock bolt on the upper side of the alternator.

Alternator Belt Tension:

(c) Adjust the lock bolt in such a way that the deflection at the midpoint between the alternator and the water pump pulley becomes the specified value when a force of 22 lb. (10 kg) is applied to the midpoint.

Specified Belt Deflection:
5 - 7 mm (0.197 - 0.276 inch) [With a force of 10 kg (22 lb.) applied to point indicated in figure].

16. Installation of air conditioner belt.

A/C Belt Alignment:

(a) Install the drive belt correctly.

(b) Adjust the drive belt tension with the adjusting bolt.

Specified Belt Deflection:
4.0 - 6.0 mm (0.16 - 0.24 inch) [With a force of 22 lb. (10 kg) applied to point indicated in figure].

A/C Idler Mount Nut:

Alternator Ground Cable:

17. Connect the ground cable connector of the alternator.

18. Install the air cleaner assembly.

Tightening Torque:
1.0 - 1.6 kg-m (7.2 - 11.6 ft-lb., 9.8 - 15.7 Nm)

Air Cleaner Hose:

19. Install the rubber hoses to the air cleaner cap according to the labels.

Air Cleaner Hose:

20. Remove the labels attached to the rubber hoses.
21. Install the air cleaner hose to the air cleaner.

Air Cleaner Hose:

22. Install the air cleaner hose to the throttle body.

PCV Hose:

23. Install the PCV hose.
24. Installation of accelerator cable.

Accelerator Cable:

(a) Install the accelerator cable to the throttle lever.

Accelerator Cable Locknut:

(c) Tighten the lock nut of the throttle body stay.

Tightening Torque:
1.0 - 1.6 kg-m (7.2 - 11.6 ft-lb., 9.8 - 15.7 Nm)

NOTE: Prevent the outer part of the throttle cable from turning during the tightening.

Cable Freeplay:

(d) Check to see if the throttle cable is pulling the throttle lever or if the throttle cable is excessively slack. If necessary, adjust the throttle cable free play.

Free play: 3 - 8 mm (0.118 - 0.315 inch).

Negative Battery Cable:

25. Connect the battery ground cable to the negative (-) terminal of the battery.