Installation

Components For Timing Belt Removal:

1. Pre-set timing belt tensioner for installation as follows:






(a) Using a press, slowly press in the push rod using 981-9,807 N (100-1,000 kg, 220-2,205 lbs.) of force.
(b) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted.
(c) Release the press.






(d) Install the dust boot onto the tensioner.
2. Install timing belt tensioner as follows:






(a) Install the tensioner with the two bolts hand tight.
(b) Alternately tighten the two bolts to 26 Nm (270 kg. cm., 20 ft. lbs.).






(c) Remove the 1.5 mm hexagon wrench from the tensioner.
3. Check camshaft timing as follows:
(a) Slowly turn the crankshaft pulley two revolutions from TDC to TDC.

NOTE: Always turn the crankshaft clockwise.






(b) Check that each pulley aligns with the timing marks as shown in the illustration.
(c) If the marks do not align, remove the timing belt and reinstall it.






4. Install the drive belt tensioner with the three bolts, then tighten to 21 Nm (210 kg. cm., 15 ft. lbs.).

NOTE: Be careful not to drop the bolts inside the timing belt cover.

5. Install No.2 timing belt cover.
6. Install No.3 timing belt cover.
7. Install PS pump front bracket and pump pulley as follows:






(a) Install the pump front bracket with the two bolts (A) hand tight.
(b) Install the plate washer and bolt (B), and tighten bolts (A) and (B) to:
Bolts (A) 8 Nm 1590 kg. cm., 43 ft. lbs.).
Bolt (B) 2 Nm (530 kg. cm., 38 ft. lbs.).
(c) Install the pump pulley with the nut hand tight.
(d) Using SST variable pin wrench and a suitable wrench, tighten the pulley nut to 43 Nm (440 kg. cm, 32 ft. lbs.).
8. Install water pump pulley, fan, fluid coupling assembly and drive belt.
9. Install radiator assembly and fill cooling system.
10. Road test, check for abnormal noise, shock, slippage, correct shift points and smooth operation.