Installation

NOTE: Check the water pump for water leakage and the oil seal for oil leakage. Repair any water leakage or oil leakage if necessary.

Tension Spring And Idler:

1. Attach the tension spring to the timing belt tensioner. Hang the tension spring hook on the pin. Assemble the timing belt tensioner in place and install the bolt.

NOTE:
^ Hang the spring hook securely on the pin groove.
^ Ensure that the pin at the oil pump is fitted into the pin hole of the timing belt tensioner.

Tensioner And Spring:

2. While pulling the timing belt tensioner fully toward the water pump side, temporarily tighten the attaching bolt of the timing belt tensioner.

Timing Belt Pulley Flange:

3. Install the crankshaft timing belt pulley flange with its recessed side facing toward the oil pump side.

Installing Crank Gear:

4. Install the crankshaft timing belt pulley on the crankshaft by aligning it with the key groove.

Installing Crank Gear Bolt:

5. Install the set bolt of the crankshaft timing belt pulley.

Removing Crank Bolt:

6. Prevent the crankshaft from being rotated by placing the gear shift lever in the 4th gear position in the case of the manual transmission vehicle; by inserting a screwdriver or the like into the ring gear at the rear end section of the cylinder block in the case of the automatic transmission vehicle. Then, tighten the set bolt of the crankshaft timing belt pulley.

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

CAUTION:
^ It should be noted that the specified torque can not be attained easily due to a slight turning of the crankshaft during the tightening.
^ Never allow the crankshaft to turn.

Cam Pulley:

7. Install the camshaft timing belt pulley on the camshaft in such a way that the "F" mark can be seen and the locating pin hole is aligned. Then, install the set bolt.

NOTE: Remove any oil or water from the camshaft timing belt pulley. Keep the pulley clean.

8. Install the attaching bolts of the camshaft timing belt pulley, while preventing the pulley from turning by inserting an iron rod into the hole of the pulley.

Tightening Torque:
1.5 - 2.2 kg-m (10.8 - 15.9 ft-lb, 14.8 - 21.5 Nm)

NOTE: Be careful not to damage the cylinder head cover gasket surface.

CAUTION: Never allow the camshaft to turn.

Cylinder Head Surface:

9. Wipe off any oil or dirt from the cylinder head cover gasket surface of the cylinder head.

Cover Gasket:

10. Check the cylinder head cover gasket for damage. Replace any gasket which exhibits damage.

NOTE: Install a new gasket in such a way that the identification mark comes at the intake manifold side.

Spark Plug Hole Grommets:

11. Check the grommets of the cylinder head spark plug tubes for damage or deformation.
Replace any grommet which exhibits damage or deformation.

Applying Sealant:

12. Apply the Three Bond 1104 to those points where the camshaft bearing caps No.1 and No.5 make contact with the cylinder head.

Installing Cover:

13. Install the cylinder head cover to the cylinder head.

NOTE:
^ Be careful not to scratch the rubber grommet for spark plug tube during installation.
^ Care must be exercised to ensure that the rubber grommet will not ride over the spark plug tube.

Torque Sequence:

14. Tighten the attaching bolts of the cylinder head cover evenly over two or three stages to the specified torque, following the sequence shown in the figure.

Tightening Torque:
0.3 - 0.5 kg-m (2.2 - 3.6 ft-lb, 3.0 - 4.9 Nm)

15. Reconnect the accelerator cable to the cable clamp.

Harness Clamp And Ground Wire:

16. Reconnect the oxygen sensor wiring harness to the clamp.
17. Install the engine ground wiring harness to the cylinder head cover. (Radio tuner equipped model only).

Tightening Torque:
0.3 - 0.5 kg-m (2.2 - 3.6 ft-lb, 3.0 - 4.9 Nm)

18. Connect the PCV hoses.

19. Connect the spark plug wires to the spark plugs. Then, connect the spark plug wires to the clamp.

NOTE: Be careful not to damage the rubber grommet of the spark plug wire.

20. Installation of timing belt.

CAUTION:
^ Do not try to pry the timing belt with a screwdriver or the like.
^ Do not allow the belt to come into contact with oil, water or dust.
^ Do not bend the belt at a sharp angle or turn the belt inside out.
^ Perform the engine turning operation at the crankshaft side.
^ Do not utilize the tension of the timing belt when tightening the set bolt of the timing belt pulley.
^ 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.
^ The adjustment of belt tension should be made when the cylinder block and its ambient temperatures are in between 5 - 50°C (41 - 122°F).

Timing Marks:

(a) Align the "F" mark of the camshaft timing belt pulley with the indicator on the cylinder head cover.

CAUTION: It should be noted that the piston may interfere with the valves if the camshaft is turned independently.

(b) Align the drilled mark of the crankshaft timing belt pulley with the indicator.

CAUTION: It should be noted that the piston may interfere with the valves if the crankshaft is turned independently.

(c) Assemble the timing belt in such a way that the two mating marks on the timing belt may be aligned with the corresponding drilled marks on the crankshaft timing belt pulley and camshaft timing belt pulley.

NOTE:
^ When the timing belt is reused, install the timing belt in such a way that there exist 34 teeth of the belt between the drilled marks of the crankshaft timing belt pulley and camshaft timing belt pulley.
^ When the timing belt is reused, install the timing belt in such a way that the arrowhead which was put during disassembly comes rotational direction of the timing belt.

Tensioner Bolt:

(d) Loosen the attaching bolt of the timing belt tensioner. Apply tension to the timing belt. Temporarily tighten the attaching bolt.

NOTE: Ensure that the belt exhibits no slack at the tension side of the belt (the side opposite to the tensioner).

Cam Position After 1.9 Turns Of Crank:

(e) Rotate the crankshaft 1.9 turns in the normal direction (to the right as viewed from the engine cylinder No.1) so that the "F" mark of the camshaft timing belt pulley comes at a point three teeth in the camshaft timing belt pulley before the indicator of the cylinder head cover.

Timing Belt Alignment:

CAUTION:
^ At this time, never turn the crankshaft reversely.
^ Make sure that the belt is not tilted between the crankshaft timing belt pulley and the camshaft timing belt pulley.
^ If the crankshaft should be reversed or the timing belt should be tilted turn the crankshaft two more turns.

(f) Make the tensioner free by loosening the attaching bolt of the timing belt tensioner.

"F" Mark:

(g) Turn the crankshaft further in the normal direction until the "F" mark of the camshaft timing belt pulley is aligned with the indicator of the cylinder head cover.

CAUTION:
^ Never turn the crankshaft reversely.
^ Never turn the crankshaft beyond the point where the "F" mark of the camshaft timing belt pulley is aligned with the indicator.
^ If the crankshaft should be reversed or turned beyond that point, temporarily tighten the tensioner attaching bolt and repeat the operations from the step (e) onward.

(h) Tighten the attaching bolt of the timing belt tensioner to the specified torque.

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

Timing Marks:

(i) Ensure that the drilled marks of the crankshaft timing belt pulley and camshaft timing belt pulley are aligned with the corresponding indicators.
If the drilled mark is not aligned with the indicator, repeat the operations from the step (a) onward.

21. Checking of timing belt tension.
When the midpoint of the belt at the tension side is pushed 5.0 mm (0.20 inch), ensure that the pushing force is 0.8 - 1.6 kg (1.77 - 3.52 lb).

Specified Pushing Force:
0.8 - 1.6 kg (1.76 - 3.52 lb, 7.84 - 15.7 N) When belt is deflected 5.0 mm (0.20 inch)

If the belt does not conform to the specification, repeat the operations from the step 20 (d) onward.

Timing Cover Fasteners:

22. Install the timing belt lower cover and upper cover.

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

NOTE: Care must be exercised as to the length of each bolt.

23. Install the crankshaft pulley with the four attaching bolts. Tighten the bolts to the specified torque.

Tightening Torque:
2.0 - 3.0 kg-m (14.5 - 21.6 ft-lb, 19.6 - 29.4 Nm)

NOTE:
^ On the manual transmission vehicle, prevent the crankshaft from turning by placing the gear shift lever in the 4th gear position.
^ On the automatic transmission vehicle, prevent the crankshaft from being rotated by inserting a screwdriver or the like into the ring gear section at the rear end section of the cylinder block.

24. Install the water pump pulley to the water pump by temporarily tightening the attaching bolt.

NOTE: On the power steering-equipped vehicle, be sure to tighten the pulley for the power steering vane pump together.

25. Install the V-ribbed belt.

26. Install the mounting front right bracket No.2.

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

Water Pump Pulley:

27. Tighten the attaching bolts of the water pump pulley by utilizing the tension of V-ribbed belt.

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

Belt Deflection:

28. Ensure that the belt deflection meets the specification when the midpoint between the water pump pulley and the alternator is pushed with a force of 10 kg (22 lb).

If the deflection does not conform to the specification, perform the adjustment so that the specification may be satisfied.

Oil Pressure Switch Wire:

29. Insert the oil pressure switch wire into the hole of the engine mounting front bracket No.1.

Oil Pressure Switch Wire Attachments Brackets:

30. Attach the oil pressure switch wire with the bolt.

Oil Pressure Switch Wire:

31. Connect the oil pressure switch wire connector to the oil pressure switch.

Front Insulator And Mounting Bracket:

32. Install the engine mounting front insulator together with the engine mounting front right bracket.

Front Insulator And Mounting Bracket Fasteners:

33. Tighten the three attaching bolts of the engine mounting front insulator.

Tightening Torque:
4.0 - 5.5 kg-m (29.0 - 39.7 ft-lb, 39.2 - 53.9 Nm)

Front Insulator And Mounting Bracket Fasteners:

34. Tighten the three attaching bolts and one nut of the engine mounting right bracket.

Tightening Torque:
Bolt: 4.0 - 5.5 kg-m (29.0 - 39.7 ft-lb, 39.2 - 53.9 Nm)
Nut: 1.5 - 2.3 kg-m (10.9 - 16.6 ft-lb, 14.7 - 22.5 Nm)

Remove the garage jack.

Air Cleaner:

35. Installation of air cleaner.
(a) Install the air cleaner to the body.

(b) Tighten the air cleaner attaching bolt.

Air Cleaner Hose:

(d) Connect the air cleaner hose from the throttle body.

36. Reconnect the battery ground cable to the negative (-) terminal of the battery.
37. Perform the engine tune-up.