Removal

COMPONENTS

TIMING BELT REMOVAL





1. Remove battery.

CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the "LO" position and the negative (-) terminal cable is disconnected from the battery.

2. Remove engine under cover.
3. Drain engine coolant.





4. Remove drive belt.
Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the drive belt.

HINT: The pulley bolt for the drive belt tensioner had left-hand thread.

5. Remove radiator reservoir tank.
(a) Disconnect the coolant level sensor connector.





(b) Disconnect the following hoses:
(1) Reservoir hose from water inlet housing.
(2) Reservoir hose from radiator.
(c) Remove the 2 bolts and reservoir tank bracket.





(d) Remove the bolt holding the reservoir tank to the radiator.
(e) Disconnect the reservoir tank from the reservoir tank bracket, and remove the reservoir tank.

6. Remove radiator assembly.
(a) Disconnect the ECT sensor connector (for cooling fan).





(b) Disconnect the ECT sensor wire clamp from the radiator fan shroud.
(c) Disconnect the following hoses:





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





(2) 2 radiator hoses.





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

HINT: Plug the hose ends.





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





(d) Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.





(e) Slightly lift the radiator, and disconnect the 2 cooler hoses (for cooling fan) from the hose clamp the radiator fan shroud.
(f) Remove the radiator assembly.
(g) Remove the 2 lower radiator supports from the radiator.

7. Disconnect air conditioning (A/C) compressor from engine.
(a) Disconnect the A/C compressor connector.





(b) Remove the nut, and disconnect the ground cable from the A/C compressor stay.
(c) Remove the bolt and A/C compressor stay.





(d) Remove the 2 bolts, and disconnect the A/C compressor from the engine.

HINT: Put aside the A/C compressor, and suspension.

8. Remove intake air connector.





(a) Disconnect the following hoses:
(1) Air hose from IAC valve.
(2) Air hose (from air control valve on PS pump) from intake air connector.
(b) Remove the bolt holding the intake air connector the cylinder head cover.





(c) Loosen the 2 hose clamps.
(d) Disconnect the intake air connector from the throttle body and air cleaner hose, and remove the intake air connector.

9. Remove LH ignition coil.





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





(b) Remove the 2 bolts and ignition coil.





10. Remove upper high-tension cord cover.
(a) Remove the 2 bolts.
(b) Disconnect the front side claw groove of the upper cord cover from the claw of lower cord cover. and remove the upper cord cover.





11. Remove RH engine wire cover.
Remove the bolt and engine wire cover.





12. Remove LH engine wire cover.
Remove the 2 bolts and engine wire cover.





13. Remove VSV for EVAP system.
Remove the 2 bolts, and disconnect the VSV from cylinder head and timing belt cover.





14. Remove RH No.3 timing belt cover.
Remove the 3 bolts. timing belt cover and 3 gasket.





15. Remove LH No.3 timing belt cover.
(a) Remove the 4 bolts.
(b) Disconnect the cord grommet from the timing belt cover, and remove the timing belt cover, and gaskets.
(c) Remove the cord grommet from the high-tension cord.

16. Remove high-tension cords, cord clam and cord cover assembly.
(a) Disconnect the No.2 high-tension cord from the cord clamp on the RH front high-tension cord clamp.





(b) Remove the 2 bolts holding the RH high-tension cord clamps to the RH cylinder head cover.
(c) Disconnect the No.1 high-tension cord from the cord clamp on the LH front high-tension cord clamp.





(d) Remove the 2 bolts holding the LH high-tension cord clamps to the LH cylinder head cover.





(e) Remove the bolt holding the lower high-tension cord cover to the RH ignition coil.
(f) Disconnect the high-tension cords from the spark plugs, distributor caps and RH ignition coil.

NOTICE: Pulling on or bending the cords may damage the conductor inside.

(g) Remove the high-tension cords, cord clamps and cord cover assembly.





17. Remove drive belt idler pulley.
Remove the pulley bolt, cover plate and idler pulley.
18. Remove RH No.2 timing belt cover.





(a) Disconnect the camshaft position sensor connector from the ignition coil bracket.





(b) Disconnect the camshaft position sensor wire from the timing belt cover.
(c) Remove the 5 bolts.
(d) Remove the connector grommet from the timing belt cover.
(e) Disconnect the camshaft position sensor wire clamp from the timing belt cover.
(f) Remove the timing belt cover and 4 gaskets.





19. Remove LH No.2 timing belt cover.
(a) Disconnect the camshaft position sensor wire from the clamp on the timing belt cover.
(b) Disconnect the camshaft position sensor connector.
(c) Remove the 3 bolts.
(d) Remove the connector grommet from the timing belt cover.
(e) Remove the timing belt cover and 2 gaskets.





20. Remove distributor caps.
Loosen the 3 bolts, and remove the distributor caps.
Remove the 2 distributor caps.

HINT: Arrange the distributor caps (RH side and LH side).





21. Remove distributor rotors.
Loosen the 2 bolts, and remove the distributor rotors.
Remove the 2 distributor rotors.

HINT: Arrange the distributor rotors (RH side and LH side).





22. Remove distributor housings.
(a) RH Distributor Housing:
Disconnect the camshaft position sensor connector.
(b) Remove the 3 bolts and distributor housing. Remove the 2 distributor housings.





23. Remove generator.
(a) Disconnect the generator connector.
(b) Remove the cap and nut, and disconnect the generator wire.
(c) Remove the bolt, and disconnect the transmission cooler pipe bracket from the generator.
(d) Remove the nut and generator.





24. Remove drive belt tensioner.
Remove the bolt, 2 nuts and belt tensioner.





25. Remove spark plugs.
Using a 16 mm plug wrench, remove the 8 spark plugs.





26. If re-using timing belt, check installation marks on timing belt.
Check that there are 4 installation marks on the timing belt by turning the crankshaft pulley as shown in the illustration.

HINT: If the installation marks have disappeared. place a new installation mark on the timing belt before removing each part.

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





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





(b) Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned.
If not, turn the crankshaft 1 revolution (360°).

28. Remove timing belt tensioner.

When Re-using Timing Belt:

HINT:
- When re-using timing belt:
If the installation marks have disappeared. before remove the timing belt, place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys, and place the a new installation mark on the timing belt to match the end of the hydraulic pump.
- When replacing timing belt tensioner only:
To avoid meshing of the timing pulley and timing belt, secure one of them with string. An matchmarks on the timing belt and RH camshaft timing pulley.





Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.

29. Disconnect timing belt from camshaft timing pulleys.





(a) Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise. SST 09278-54012





(b) Disconnect the timing belt from the camshaft timing pulleys.





30. Remove camshaft timing pulleys.
Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. SST 09278-54012
31. Remove crankshaft pulley.





(a) Using SST, remove the pulley bolt. SST 09213-70010,09330-00021





(b) Using SST, remove the crankshaft pulley. SST 09213-31021

32. Remove hydraulic pump.





HINT (When re-using timing belt): Before removing the hydraulic pump, using the crankshaft pulley bolt, turn the crankshaft pulley and align the installation mark of the timing belt with the end of the hydraulic pump.





(a) Disconnect the solenoid valve connector.
(b) Remove the 2 bolts and 2 nuts.
(c) Disconnect the crankshaft position sensor wire clamp.
(d) Remove the hydraulic pump.





33. Remove No.1 timing belt cover.
Remove the 4 bolts, timing belt cover and gasket.





34. Remove timing belt cover spacer.
Remove the belt cover spacer and gasket.





35. Remove timing belt guide (crankshaft angle sensor plate).





36. Remove timing belt.

HINT (When re-using timing belt): If the installation marks have disappeared, place a new installation mark on the timing belt to the match the dot mark on the crankshaft timing pulley.





37. Remove No.2 idler pulley.
Remove the bolt and idler pulley.





38. Remove No.1 idler pulley.
Using a 10 mm hexagon wrench, remove the bolt, idler pulley and plate washer.





39. Remove crankshaft timing pulley.
Using SST, remove the timing pulley. SST 09213-60017 (09213-00050)