Timing Belt Installation

Components For Timing Belt Removal:

1. Install crankshaft timing pulley as follows:






(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley facing the flange s inward.

NOTE: Do not scratch the sensor part of the crankshaft timing pulley.

(c) Install the timing belt plate with the bolt and tighten to 7.8 Nm (80 kg. cm., 69 inch lbs.).

2. Install tensioner idler pulley as follows:






(a) Apply LOCTITE 242, or equivalent, adhesive to two or three threads of the pivot bolt.
(b) Using a ten mm hexagon wrench, install the plate washer and pulley with the pivot bolt and tighten to 34 N m (350 kg. cm., 25 ft. lbs.).
(c) Check that the pulley bracket moves smoothly.

3. Install timing belt to crankshaft sprocket as follows:

NOTE: The engine should be cold.






(a) Using the crankshaft pulley bolt, turn the crankshaft, and align the timing marks on the crankshaft timing pulley and on the oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.






(c) Install the timing belt on the crankshaft timing pulley and idler pulley.

NOTE: When re-using a timing belt, align the match marks of the crankshaft timing pulley and timing belt made at removal, and install the belt with the arrow pointing in the direction of engine revolution.






4. Install the timing belt guide, facing the cup side outward.

5. Install No.1 Timing belt cover.

6. Install crankshaft pulley as follows:
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.






(b) Using companion flange holder Special Service Tool (SST) No. 09330-00021 with 09213-70010, or equivalent, install the bolt and tighten to 324 Nm (3,300 kg. cm., 239 ft. lbs.).

7. On models with Automatic Transmission (A/T), connect oil cooler tubes.

8. Install camshaft timing pulleys as follows:






(a) Align the camshaft knock pin with the groove of the pulley, and slide on the timing pulley.
(b) Install the timing pulley bolts hand tight.






(c) Using variable pin wrench SST No. 09962-01000, or equivalent, tighten the pulley bolts to 79 Nm (810 kg. cm., 59 ft. lbs.).

9. Set No.1 cylinder to TDC / Compression as follows:






(a) Turn the crankshaft pulley, and align its groove with timing mark -0- of the No.1 timing belt cover.

NOTE: Always turn the crankshaft clockwise.






(b) Using SST variable pin wrench, align the timing marks of the camshaft timing pulleys and No.4 timing belt cover.

10. Install timing belt to camshaft pulleys as follows:






NOTE: When re-using timing belt, align the matchmarks of the timing belt and camshaft timing pulleys made at disassembly.

(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 exhaust camshaft timing pulley.

11. 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.

12. 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.

13. 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.






14. 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.

15. Install No.2 timing belt cover.

16. Install No.3 timing belt cover.

17. 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) 58 Nm 1590 kg. cm., 43 ft. lbs.).
Bolt (B) 52 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.).

18. Install water pump pulley, fan, fluid coupling assembly and drive belt.

19. Install radiator assembly and fill cooling system.

20. Road test, check for abnormal noise, shock, slippage, correct shift points and smooth operation.