Timing Belt Installation
1. Install Oil Pump Pulleya. Align the cutouts of the pulley and shaft,and slide the pulley.
Timing Belt Installation:
b. Using SST, install and torque the nut. SST 09616-30011
Torque: 28 Nm (21 ft.lb)
Installing Crankshaft Timing Pulley:
2. Install Crankshaft Timing Pulley
a. Align the pulley set key with the key groove of the pulley, slide the pulley.
Installing No. 2 Idler Pulley:
3. Install No.2 Idler Pulley
a. Install the pulley with the bolt. Torque the bolt.
Torque: 43 Nm (32 ft.lb)
b. Check that the pulley moves smoothly.
Timing Belt Installation:
4. Temporarily Install No.1 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 it.
NOTE: Remove any oil or water on the idler pulley and keep it clean.
Timing Belt Installation:
5. Temporarily Install Timing Belt
CAUTION: The engine should be cold.
a. Install the timing belt on the crankshaft timing, oil pump, No.2 idler and water pump pulleys.
NOTE: 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.
Timing Belt Installation:
6. Install Timing Belt Guide
a. Install the guide, facing the cup side outward.
Timing Belt Installation:
7. Install No.1 Timing Belt Cover
a. Install the gasket to the belt cover.
b. Install the belt cover with the six bolts.
Torque: 8.8 Nm (78 in.lb)
Timing Belt Installation:
8. Install Crankshaft Pulley
a. Align the pulley set key with the key groove of the pulley, slide the pulley.
b. Using SST, install and torque the bolt. SST 09213-14010 and 09330-00021
Torque: 108 Nm (80 ft.lb)
Timing Belt Removal:
9. Set No.1 Cylinder To TDC/Compression
a. Check that the crankshaft pulley groove align with the "0" mark on the No.1 timing belt cover.
b. If Not aligned, turn the crankshaft pulley and align its groove with the "0" mark the No.1 timing belt cover.
NOTE: There are two types of camshafts, one with two holes on the timing pulley contact surface and one with five holes on the timing pulley contact surface. All replacement camshaft have five holes.
Timing Belt Installation:
(Two Hole Type)
b. Using a wrench, turn the camshafts so that the camshaft knock pin aligns with the matchmark of the No.3 timing belt cover. And the No.1 cam of the camshaft is as shown in the figure.
Timing Belt Installation:
(Five Hole Type)
c. Using a wrench, turn and align the camshaft knock pin and the No.1 bearing cap mark camshaft as shown in the figure.
10. Install Camshaft Timing Pulleys And Timing Belt
NOTE: There are two types of camshaft timing pulleys, one with five holes on the camshaft contact surface, and one with one hole on the camshaft contact surface. All replacement pulleys have five holes.
a. Hang the timing belt on the pulleys.
NOTE:
- If reusing the timing belt, align the point marked during removal.
- The "S" mark on the timing pulley should face outward.
b. Align the timing pulley matchmark with the No.3 timing belt cover matchmark. And install the timing pulleys with the belt.
Timing Belt Installation:
(One Hole Type)
c. Match the camshaft knock pin with the camshaft timing pulley hole.
Timing Belt Installation:
(Five Hole Type)
d. Insert the knock pin into whichever camshaft timing pulley and camshaft holes are aligned.
NOTE: If not matched, align the camshaft timing pulley hole with the camshaft hole by turning the camshaft a little.
Timing Belt Installation:
e. Hold the camshaft with a wrench, and tighten the bolts.
Torque: 59 Nm (43 ft.lb)
Timing Belt Installation:
e. Loosen the No.1 idler pulley mount bolt and stretch the timing belt.
NOTE: Do not loosen the mount bolt further than the point where the idler returns.
Timing Belt Removal:
f. Turn the crankshaft pulley two revolutions from TDC to TDC.
NOTE: Always turn the crankshaft clockwise.
Timing Belt Installation:
g. Torque the mount bolt of the No.1 idler pulley.
Torque: 43 Nm (32 ft.lb)
Timing Belt Installation:
h. Check that the belt has tension between the crank- shaft timing pulley and the camshaft timing pulley of the intake side.
Timing Belt Installation:
11. Install No.2 Timing Belt Cover
a. Install the gasket to the belt cover.
b. Install the belt cover with the five bolts.
12. Install Spark Plugs
Torque: 18 Nm (13 ft.lb)
13. Install Cylinder Head Covers
a. Apply seal packing to the cylinder head as shown in the image.
Seal Packing: Part No. 08826-00080 or equivalent
b. Install the gasket and two head covers with screws.
c. Install the gasket and center cover with the screws.
Torque: 5.4 Nm (48 in.lb)
Timing Belt Installation:
14. Install Engine Right Hand Mounting Insulator And Bracket
a. Install the bracket with the three bolts. Torque the bolts.
Torque: 52 Nm (38 ft.lb)
b. Install the mounting insulator with the two nuts and through bolt.
Torque:
Bolt: 78 Nm (58 ft.lb)
Nut: 52 Nm (38 ft.lb)
15. Lower Engine
16. Install Power Steering Pump
17. Install Alternator Bracket
Torque: 39 Nm (29 ft.lb)
18. Install Alternator
19. Install Drive Belts
a. Adjust the drive belts
Drive belt tension:
Alternator w/ Air con: New belt 125 +/- 25 lb
Used belt 80 +/- 20 lb
Alternator w/o Air con: New belt 150 +/- 25 lb
Used belt 130 +/- 25 lb
Power Steering pump: New belt 125 +/- 25 lb
Used belt 80 +/- 20 lb
20. Install Power Steering Oil Reservoir Tank
21. Install Cruise Control Actuator And Bracket
22. Install Radiator Reservoir Tank
23. Install Engine Right Hand Under Cover
24. Install Right Hand Front Wheel
25. Connect Cable To Negative Terminal Of Battery