Installation
1. Set timing belt tensioner for installation as follows:
(a) Using a press, slowly press in the push rod using 981-9,807 N (220-2,205 lbs.) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon (Allen) wrench through the holes to keep the setting position of the push rod.
(c) Release the press.
(d) Install the dust boot to the belt tensioner.
2. Install timing belt tensioner as follows:
(a) Install the belt tensioner with the two bolts hand tight.
(b) Alternately tighten the two bolts, final tighten to 26 Nm (19 ft. lbs.).
(c) Using pliers, remove the 1.27 mm hexagon (Allen) wrench from the belt tensioner.
3. Check valve timing as follows:
(a) Install the crankshaft pulley bolt hand tight.
(b) Slowly turn the crankshaft pulley in a clockwise direction two revolutions from TDC to TDC.
NOTE: Always turn the crankshaft pulley clockwise.
(c) Check that each pulley aligns with the timing marks as shown in the illustrations.
(d) If the timing marks do not align, remove the timing belt and reinstall it.
4. Using crankshaft pulley holder SST No. 09213-54015 and companion flange holder SST No. 09330-00021, or equivalent, tighten the pulley bolt to 245 Nm (181 ft. lbs.).
5. Install the hydraulic pump, solenoid valve connector clamp and the crankshaft position sensor wire clamp with the two bolts and two nuts positioned as shown in the illustration, tighten as follows:
Bolt length A: 106 mm (4.17 inch) for 12 mm head tighten to 16 Nm (12 ft. lbs.).
Bolt length B: 114 mm (4.49 inch) for 14 mm head tighten to 30 Nm (22 ft. lbs.).
NOTE: Each bolt length is indicated in the illustration.
6. Install the A/C compressor.
7. Install No. 1 ignition coil, refer to Powertrain Management.
8. Install distributor housings, refer to Powertrain Management.
9. Install RH No. 2 timing belt cover as follows:
(a) Install the four gaskets to the timing belt cover.
(b) Install the wire grommet to the timing belt cover.
(c) Fit the timing belt cover, matching it with the fan bracket.
(d) Fit the timing belt cover holes, matching them with the two grommets on the distributor.
(e) Install the timing belt cover with the four bolts, tighten 12 mm x 106 mm (4.170 inch) in length bolts to 16 Nm (12 ft. lbs.).
(f) Install the No. 2 camshaft position sensor wire to the wire clamp on the timing belt cover.
(g) Install the wire clamp to the timing belt cover.
(h) Install the sensor connector to the ignition coil bracket.
10. Install LH No. 2 timing belt cover as follows:
(a) Install the two gaskets to the timing belt cover.
(b) Run the No. 1 camshaft position sensor wire through the timing belt cover hole.
(c) Fit the timing belt cover, matching it with the fan bracket.
(d) Fit the timing belt cover holes, matching them with the two grommets on the distributor.
(e) Install the timing belt cover and connector bracket with the three bolts.
(f) Install the wire grommet to the timing belt cover.
(g) Install the sensor connector to the connector bracket. Connect the sensor connector.
(h) Install the sensor wire to the wire clamp on the timing belt cover.
(i) Install the engine wire to the two wire clamps on the timing belt cover.
11. Install the drive belt idler pulley and cover plate with the bolt, tighten to 37 Nm (27 ft. lbs.).
12. Install RH No. 3 timing belt cover as follows:
(a) Install the two gaskets to the timing belt cover.
(b) Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
(c) Install the timing belt cover with the four bolts.
13. Install LH No. 3 timing belt cover as follows:
(a) Install the two gaskets to the timing belt cover.
(b) Install the cord grommet to the high-tension cord (from the LH ignition coil).
(c) Install the cord grommet to the timing belt cover.
(d) Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
(e) Install the timing belt cover with the four bolts.
14. Install radiator assembly.
15. Install air cleaner.
16. Install intake air connector assembly.
17. Install V-bank cover.
18. Fill with engine coolant.
19. Start engine and check for leaks.
20. Check engine coolant level.
21. Install battery clamp cover.
22. Install engine under cover.