Timing Belt Installation
INSTALLATION OF TIMING BELT
1. Install oil pump pulley.
(a) Align the cutouts of the pulley and shaft, and slide the pulley.
(b) Using SST 09616-30011, install the nut.
Torque: 35 N.m (355 kgf.cm, 26 ft.lbf)
2. Install crankshaft timing pulley.
(a) Align the 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: 43 N.m (440 kgf.cm, 32 ft.lbf)
(b) Check that the idler pulley moves smoothly.
4. Install No.1 idler pulley.
(a) Apply adhesive to two or three threads of the pivot bolt.
Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(b) Install the plate washer and pulley with the pivot bolt.
Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
(c) Check that the pulley bracket moves smoothly.
5. Temporarily install timing belt.
NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft and face the key groove of the crankshaft timing pulley upward.
(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.2 idler pulley, water pump pulley and No.1 idler pulley.
HINT: (When re-using timing belt)
Align the matchmarks of the crankshaft timing pulley and timing belt, 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 six 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 09213-54015 (90119-08216) and 09330-00021, install and torque the bolt.
Torque: 108 N.m (1,100 kgf.cm, 80 ft.lbf)
9. Install camshaft timing pulleys.
(a) Using a wrench, turn and align the groove of the camshaft with the drilled mark of the No.1 camshaft bearing cap.
(b) Slide the timing pulley onto the camshaft, facing mark "S" upward.
(c) Align the pin holes of the camshaft and timing pulley, and insert the knock pin.
(d) Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the bolts.
Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) 41 N.m (420 kgf.cm, 30 ft.lbf)
HINT: (Intake camshaft timing pulley)
^ Use SST 09249-63010
^ 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) Turn the camshaft, and align the timing marks of the camshaft timing pulleys and No.3 timing belt cover.
11. Install timing belt.
HINT: (When re-using timing belt)
^ Check that the matchmark on the timing belt matches the end of the No.1 timing belt cover. If the matchmark does 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 pulleys.
(a) Remove any oil or water on the camshaft timing pulley, and keep it clean.
(b) Install the timing belt, checking the tension between the crankshaft timing pulley and intake camshaft timing pulley.
12. Set timing belt tensioner.
(a) Using a press, slowly press in the push rod using 100 - 1000 kg (220 - 2,205 lb, 981 - 9,807 N) 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.
13. Install timing belt tensioner.
(a) Turn the No.1 idler pulley bolt counterclockwise to obtain the specified torque toward the left as far as the No.1 idler pulley will go, and temporarily install the tensioner with the two bolts
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
NOTICE: To apply the correct torque, apply the torque wrench along the axis through the bolts of the No.1 idler pulley and exhaust camshaft timing pulley.
(b) Slowly turn the crankshaft pulley 5/6 revolution, and align its groove with the ATDC 60° mark of the No.1 timing belt cover.
NOTICE: Always turn the crankshaft clockwise.
(c) Insert a 1.90 mm (0.075 in.) feeler gauge between the tensioner body and No.1 idler pulley stopper.
(d) Turn the No.1 idler pulley bolt counterclockwise to obtain the specified torque.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
NOTICE: To apply the correct torque, apply the torque wrench along the axis through the bolts of the No.1 idler pulley and exhaust camshaft timing pulley.
(e) While pushing the tensioner, alternately tighten the two bolts.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
(f) Remove the 1.90 mm (0.075 in.) feeler gauge.
(g) Remove the 1.27 mm hexagon wrench from the tensioner.
(h) Slowly turn the crankshaft pulley one revolution, and align its groove with the ATDC 60° mark of the No.1 timing belt cover.
NOTICE: Always turn the crankshaft clockwise.
(i) Using a feeler gauge, check the specified clearance between the tensioner body and No.1 idler pulley stopper. If the clearance is not as specified, remove the tensioner and reinstall it.
Clearance: 1.80-2.20 mm (0.071 - 0.087 in.)
14. Check valve timing.
(a) Slowly turn the crankshaft pulley two revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it.
15. Install No.2 timing belt cover.
(a) Install the gasket to the timing belt cover.
(b) Install the belt cover with the five bolts.
16. Install spark plugs.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
17. Install cylinder head cover.
18. Install RH engine mounting bracket.
Install the mounting bracket with the three bolts.
Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
19. Install RH engine mounting insulator.
Install the mounting insulator with the through bolt and two nuts
Torque:
Through bolt 87 N.m (890 kgf.cm, 64 ft.lbf)
Nut 52 N.m (530 kgf.cm, 38 ft.lbf)
20. Install RH engine mounting stay.
Install the mounting stay with the bolt and nut.
Torque: 73 N.m (740 kgf.cm, 54 ft.lbf)
21. Install PS drive belt.
Install the drive belt with the pivot bolt and adjusting bolt.
22. Install throttle body.
23. Install EGR valve and pipe.
24. Install EGR vacuum modulator and VSV.
25. Install charge air cooler.
26. Install generator.
27. Install RH engine under cover.
28. Connect cable to negative terminal of battery.
29. Check and adjust drive belts.
Alternator belt tension:
With A/C New belt 165 ± 10 lbf
Used belt 84 ± 15 lbf
Without A/C New belt 150 ± 25 lbf
Used belt 130 ± 20 lbf
P/S belt tension: New belt 125 ± 25 lbf
Used belt 80 ± 20 lbf
30. Install RH front wheel.