Timing Belt Installation

INSTALLATION OF TIMING BELT

1. Install camshaft timing pulleys.





(a) Position the knock pin of the camshafts as shown in the figure.
(b) Align the camshaft knock pin with the knock pin groove of the pulley, and slide the pulley, facing the timing mark upward.





(c) Secure the hexagonal wrench head portion of the camshaft, and install the plate washer and bolt. Torque the bolt.

Torque: 600 kg-cm (43 ft-lb, 59 N.m)

NOTE:
- Remove any oil or water on the camshaft timing pulley and keep it clean.
- Be careful not to damage the cylinder head with the wrench.

2. Install cylinder head covers.
(a) Apply seal packing to the cylinder head as shown the illustration.

Seal packing: Part No.08826-00080 or equivalent

(b) Install the intake and exhaust head covers with the gaskets.
(c) Install the center cover with the gasket.
(d) Install the PCV hose.

3. Install crankshaft timing pulley.
Install the crankshaft timing pulley and align the TDC marks on the oil pump body and crankshaft timing pulley.

HINT: Remove any oil or water on the crankshaft timing pulley and keep it clean.





4. Temporarily install idler pulley and tension spring.
(a) Install the pulley with the bolt. Do not tighten the bolt yet.
(b) Install the tension spring.
(c) Pry the pulley toward the left as far as it will go and tighten the bolt.





5. Set No.1 cylinder to TDC/Compression.
(a) Align the timing marks of the camshaft timing pulleys and No.4 timing belt cover by turning the camshafts.
(b) Align the timing marks of the crankshaft timing pulley and oil pump body by turning the crankshaft.

6. Install timing belt.

NOTICE: The engine should be cold.





HINT: If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.





Install the timing belt, checking the tension between the intake camshaft and crankshaft timing pulleys.
7. Check valve timing and timing belt deflection.





(a) Slowly loosen the idler pulley bolt.





(b) Temporarily install the crankshaft pulley bolt, and turn the crankshaft pulley two revolutions from TDC to TDC.

HINT: Always turn the crankshaft clockwise.





(c) 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.





(d) Torque the idler pulley bolt.

Torque: 375 kg-cm (27 ft-lb. 37 N.m)





(e) Check that there is belt deflection at the position indicated in the illustration.

Deflection: 4 mm (0.16 in.) at 2 kg (4.4 lb, 20 N)





If the deflection is not as specified, adjust with the idler pulley.
(f) Remove the temporarily installed crankshaft pulley bolt.





8. Install timing belt guide.
Install the guide, facing the cup side outward.
9. Install timing belt covers.
(a) Install the gaskets 10 the belt covers.
(b) Install the No.1, No.2 and No.3 belt covers and support plate with the ten bolts.





HINT: Each bolt length is indicated in the illustration.

10. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, slide the pulley.





(b) Using SST 09213-70010 and 09330-00021, install and torque the bolt.

Torque: 1,400 kg-cm (101 ft-lb 137 N.m)

11. Temporarily install water pump pulley.
12. Install RH engine mounting insulator.





(a) Install the RH engine mounting insulator to the engine with two nuts.
Align the RH mounting insulator into the bracket arid install the mounting through bolt.

Torque:
Nut 530 kg-cm (38 ft-lb, 52 N.m)
Through bolt 890 kg-cm (64 ft-lb, 87 N.m)





(b) Install the RH mounting stay and three bolts, remove the jack.

Torque: 430 kg-cm (31 ft-lb, 42 N.m)

13. Install spark plugs.





(a) Using a plug wrench (16 mm), install the spark plugs.

Torque: 180 kg-cm (13 ft-lb, 18 N.m)

(b) Connect the high-tension cords to the spark plugs.





(c) Install the plug cord cover with the bolts.





14. Connect engine wire to No.4 timing belt cover.
(a) Connect the engine wire to the timing belt cover.
(b) Connect the following connectors:
- Distributor wire connectors
- Oil pressure sender gauge connector
- (with A/C) Compressor connector





15. Install alternator drive belt and tighten water pump pulley bolts.
(a) Place the drive bolt on each pulley.
(b) Stretch the belt tight and tighten the four water pump pulley bolts.

16. On vehicles with PS and/or A/C, install PS and/or A/C drive belt.
17. Adjust drive belts.
Using a belt tension gauge, adjust the drive belt tension.

Drive belt tension:
Alternator
New belt 175 ± 5 lb
Used belt 115 ± 20 lb
P/S and/or A/C
New belt 165 ± 25 lb
Used belt 90 ± 20 lb





18. Install radiator inlet hose and high-tension cord.
19. On vehicles with cruise control, install cruise control actuator.





(a) Install the actuator with the bracket and three bolts.





(b) On vehicles with PS, Install the three pipe clamps with the bolts.
(c) On vehicles with PS, Install the PS reservoir tank with the bolt.

20. Install washer tank.
21. Refill engine coolant.
22. Start engine and check for leakage.
23. Install RH engine under cover.
24. Install RH front wheel.