Installation

COMPONENTS

TIMING BELT INSTALLATION

1. install crankshaft timing pulley.
(a) Align the timing pulley set key with the key groove of the pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-46011

2. Install No.1 idler pulley.
(a) Apply adhesive 2 or 3 threads of the pivot bolt.

Adhesive: Pert No.06833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

(b) Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt.

Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)

(c) Check that the pulley bracket moves smoothly.

3. Install No.2 idler pulley.
(a) Install the idler pulley with the bolt.

Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)

(b) Check that the idler pulley moves smoothly.

4. Temporarily install timing belt.

NOTICE: The engine should be cold.

(a) Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body.
(b) Remove any oil or water on the crankshaft pulley. pump pulley. water pump pulley. No.1 idler pulley No.2 idler pulley, and keep them clean.

(c) Align the installation mark on the timing belt with the dot mark of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley No.1 idler pulley and No.2 idler pulley.

5. Install timing belt guide (crankshaft angle sensor plate).
Install the belt guide, facing the cup side outward.

6. Install timing belt cover spacer.
(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.

7. Install No.1 timing belt cover.
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the 4 bolts.

8. Install hydraulic pump.
(a) Install the hydraulic pump. solenoid valve connector clamp and crankshaft position sensor wire clamp with the 2 bolts and 2 nuts.

Torque:
16 Nm (160 kgf-cm, 12 ft-lbf) for 12 mm head
30 Nm (310 kgf-cm, 22 ft-lbf) for 14 mm head

HINT: Each bolt length is indicated in the illustration.

Bolt length:
106 mm (4.17 in.) for A of 12 mm head
114 mm (4.49 in.) for B of 14 mm head

(b) Connect the solenoid valve connector.

9. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the crankshaft pulley.

(b) Using SST and a hammer, tap in the crankshaft pulley. SST 09223-46011

10. Install RH camshaft timing pulley.
(a) Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the "R" mark forward.
(c) Using SST, install the pulley bolt. SST 09278-54012

Torque: 108 Nm (1,100 kgf-cm, 80 ft-lbf)

11. Install LH camshaft timing pulley.
(a) Align the camshaft knock pin with the knock groove of the timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the "L" mark forward.
(c) Using SST, install the pulley bolt. SST 09278-54012

Torque: 108 Nm (1,100 kgf-cm, 80 ft-lbf)

12. Set No.1 cylinder to TDC/Compression.

(a) Crankshaft Pulley Position:
Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.

(b) (Camshaft Timing Pulley Position)
Using SST, turn the camshaft timing pulley, and align the timing marks of the camshaft timing pulley and timing belt rear plate. SST 09278-54012

13. Connect timing belt to LH camshaft timing pulley.

(a) Align the installation mark on the timing belt with the end of the hydraulic pump.
(b) Remove any oil or water on the LH camshaft timing pulley, and keep it clean.

(c) Using SST, slightly turn the LH camshaft timing pull clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley. SST 09278-54012

(d) Using SST, align the timing marks of the LH camshaft timing pulley and timing belt rear plate. SST 09278-54012
(e) Check that the timing belt has tension between the crankshaft timing pulley and LH camshaft timing pulley.

14. Connect timing belt to RH camshaft timing pulley.
(a) Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep them clean.

(b) Using SST. slightly turn the RH camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley. SST 09278-54012

(c) Using SST, align the timing marks of the RH camshaft timing pulley and timing belt rear plate. SST 09278-54012
(d) Check that the timing belt has tension between the RH camshaft timing pulley and LH camshaft timing pulley.

15. Set timing belt tensioner.
(a) Using a press, slowly press in the push rod using 981-9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of force.

(b) Align the holes of the push rod and housing. pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
(c) Release the press.

(d) Install the dust boot to the belt tensioner.

16. Install timing belt tensioner.
(a) Temporarily install the belt tensioner with the 2 bolts.

(b) Alternately tighten the 2 bolts.

Torque: 28 Nm (270 kgf-cm, 20 ft-lbf)

(a) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

NOTICE: Always turn the crankshaft pulley clockwise.

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

18. Install spark plugs.
Using a 16 mm plug wrench, install the 8 spark plugs.

Torque: 18 Nm (180 kgf-cm, 13 ft-lbf)

19. Install drive belt tensioner.
Install the belt tensioner with the bolt and 2 nuts.

Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)

HINT: Use bolt 106 mm (4.18 in.) in length.

20. Install generator.
(a) Install the generator and transmission oil cooler pipe bracket with the bolt and nut.

Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

(b) Connect the generator connector.
(c) Connect the generator wire with the nut and cap.

21. Install RH distributor housing.
Install the distributor housing with the 3 bolts.

Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

HINT:
- The RH distributor housing is marked with "R".
- Each bolt length is indicated in the illustration.

Bolt length:
38 mm (1.50 in.) for A
96 mm (3.78 in.) for B

22. Install LH distributor housing.
Install the distributor housing with the 3 bolts.

Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

HINT:
- The LH distributor housing is marked with "L".
- Each bolt length is indicated in the illustration.

Bolt length:
38 mm (1.50 in.) for A
80 mm (3.15 in.) for B

23. Install distributor rotors.
(a) Align the protrusion of the distributor rotor with the groove the camshaft timing pulley.
(b) Install the distributor rotor with the 2 bolts. Install the 2 distributor rotors.

Torque: 3.8 Nm (39 kgf-cm, 34 in-lbf)

24. Install distributor caps.
Install the distributor cap with the 3 bolts. Install the 2 distributor caps.

Torque: 3.8 Nm (39 kgf-cm, 34 in-lbf)

25. Install RH No.2 timing belt cover.

(a) Install the 4 gaskets to the timing belt cover.
(b) Install the wire grommet to the timing belt cover.
(c) Fit the timing belt cover, matching it with the hydraulic pump.
(d) Fit the timing belt cover holes. matching them with the 2 grommets on the distributor cap.
(e) Install the timing belt cover with the 5 bolts.

Torque: 18 Nm (185 kgf-cm, 13 ft-lbf) for 12 mm head

HINT (for 12 mm head): Use bolts 106 mm (4.17 in.) length.

(f) Install the wire clamp to the timing belt cover.
(g) Install the camshaft position sensor connector ignition coil bracket.

26. Install LH No.2 timing belt cover.
(a) Install the 2 gaskets to the timing belt cover.
(b) Run the camshaft position sensor wire through the timing belt cover hole.
(c) Fit the timing belt cover, matching it with the hydraulic pump.
(d) Fit the timing belt cover holes, matching them with the 2 grommets on the distributor cap.
(e) Install the timing belt cover and connector bracket with the 3 bolts.
(f) Install the wire grommet to the timing belt cover.
(g) Install the camshaft position sensor connector to the connector bracket.

27. Install drive belt idler pulley.
Install the idler pulley and cover plate with the bolt.

Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

28. Install high-tension cords, cord clamps and cord cover assembly.
(a) Connect the high-tension cords to the spark plugs, distributor caps and RH ignition coil.

(b) Install the lower high-tension cord cover with the bolt.
(c) Connect the RH front high-tension cord clamp to the lower high-tension cord cover.
(d) Place the RH front high-tension cord clamp to the RH rear high-tension cord clamp.

(e) Install the 2 bolts holding the RH high-tension cord clamps to the RH cylinder head cover.
(f) Connect the No.2 high-tension cord to the cord clamp on the RH front high-tension cord clamp.
(g) Connect the LH front high-tension cord clamp to the lower high-tension cord cover.
(h) Place the LH front high-tension cord clamp to the LH rear high-tension cord clamp.

(i) Install the 2 bolts holding the LH high-tension cord clamps to the LH cylinder head cover.
(j) Connect the No.1 high-tension cord to the cord clamp on the LH front high-tension cord clamp.

29. Install RH No.3 timing belt cover.
(a) Install the 3 gaskets to the timing belt cover.
(b) Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
(c) Install the timing belt cover with the 4 bolts.

30. Install VSV for EVAP system.
Install the VSV with the 2 bolts.

31. Install LH No.3 timing belt cover.
(a) Install the 3 gaskets to the timing belt cover.
(b) Install the cord grommet to the high-tension cord (from the LH ignition coil).
(c) Install the cord grommet to the timing belt cover.
(d) Fit the portion A of the timing belt cover, matching with the lower high-tension cord cover.
(e) Install the timing belt cover with the 4 bolts.

32. Install RH engine wire cover.
(a) Fit portions A and B of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
(b) Install the timing belt cover with the bolt.

33. Install LH engine wire cover.
(a) Connect portions A and B of the engine wire cover the wire brackets.
(b) Set the VSV (for the fuel pressure) wire in original position.
(c) Fit portions C and D of the engine wire cover, matching them with the lower high-tension cord cover a No.3 timing belt cover.
(d) Install the timing belt cover with the 2 bolts.

34. Install upper high-tension cord cover.

(a) Fit portion A of the upper high-tension cord cover matching the top of the lower high-tension cord cover.

(b) Push the front side of the upper high-tension cord cover. and fit the front side claw groove of the upper high-tension cord cover to the claw of the lower high-tension cord cover.
(c) Install the upper high-tension cord cover with the 2 bolts.

35. Install LH ignition coil.

(a) Install the ignition coil with the 2 bolts.

(b) Connect the following connectors and cord:
(1) Ignition coil connector.
(2) Noise filter connector.
(3) High-tension cord.

36. Install intake air connector.

(a) Connect the intake air connector to the throttle body.
(b) Install the hose clamp and bolt.

(c) Connect the following hoses:
(1) Air hose to IAC valve.
(2) Air hose (from air control valve on PS pump) to intake air connector.

37. Install air conditioning (A/C) compressor.
(a) Install the A/C compressor, compressor stay and ground cable with the nut and 3 bolts.

Torque:
49 Nm (500 kgf-cm, 36 ft-lbf) for bolt
29 Nm (300 kgf-cm, 22 ft-lbf) for nut

(b) Connect the A/C compressor connector.

38. Install radiator assembly.

(a) Install the 2 lower radiator supports to the radiator.
(b) Place the radiator assembly on the body bracket.

(c) Slightly lift the radiator, and connect the 2 oil cooler hoses (for cooling fan) to the hose clamp on the radiator fan shroud.

(d) Install the upper radiator support with the 2 bolts a screw. Install the 2 upper radiator supports.

Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)

(e) Connect the following hoses:

(1) 2 oil cooler hoses (for cooling fan) to pipes.

(2) 2 radiator hoses.

(3) 2 oil cooler hoses (for transmission) to radiator.

(4) Suction hose to hydraulic pump.
(5) Pressure hose to hydraulic pump.

(f) Connect the ECT sensor connector (for cooling fan).
(g) Install the ECT sensor wire clamp to the radiator fan shroud.

39. Install radiator reservoir tank.
(a) Install the reservoir tank to the reservoir tank bracket.

(b) Install the reservoir tank with the bracket and 3 bolts.

Torque: 4.9 Nm (50 kgf-cm, 43 in-lbf)

(c) Connect the following hoses:
(1) Reservoir hose to water inlet housing.
(2) Reservoir hose to radiator.
(d) Connect the coolant level sensor connector.

40. Install drive belt.
Install the drive belt by turning the drive belt tension counterclockwise.

HINT: The pulley bolt for the dive belt tensioner has a left hand thread.

41. Install battery.
42. Fill with engine coolant.
43. Start engine and check for leaks.
44. Check transmission fluid level.
45. Install engine under cover.