Installation

Components For Removal And Installation:

1. Install the 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 N.m (12 ft.lb) for 12 mm head
30 N.m (22 ft.lb) 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.





2. Connect pressure and suction hoses to hydraulic pump:
a. Connect the pressure hose with a new gasket and the union bolt. Torque union bolt to: 64 N.m (47 ft.lb).
b. Connect the suction hose.





3. 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 N.m (13 ft.lb) for 12 mm head
HINT (for 12 mm head): Use bolts 106 mm (4.17 in.) in length.
f. Install the wire clamp to the timing belt cover.
g. Install the camshaft position sensor wire to the wire clamp on the timing belt cover.





h. Except California Models: Install the camshaft position sensor connector to the ignition coil bracket.





4. 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 wire to the wire clamp on the timing belt cover.
h. Install the camshaft position sensor connector to the connector bracket.





5. Install the drive belt idler pulley and cover plate with the bolt. Torque the bolt to: 37 N.m (27 ft.lb).
6. Connect radiator hose to water inlet.





7. Install RH No. 3 timing belt engine 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.





8. 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 it with the lower high-tension cord cover.
e. Install the timing belt cover with the 4 bolts.





9. 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.





10. Install LH engine wire cover:
b. Connect portions A and B of the engine wire cover to 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 and No.3 timing belt cover.
d. Install the timing belt cover with the 2 bolts.





11. 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.





12. Install air intake connector:
a. Connect the intake air connector to the throttle body.
b. Install the bolt and 2 hose clamps.





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





13. 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





14. Install Air Conditioning compressor:
a. Install the A/C compressor, compressor stay and ground cable with the nut and 3 gaskets. Torque: 49 N.m (36 ft.lb) for bolt. 29 N.m (22 ft.lb) for nut.
b. Connect the A/C compressor connector.





15. Install the drive belt by turning the drive belt tensioner counterclockwise. The pulley bolt for the dive belt tensioner has a lefthand thread.





16. Install battery.
17. Fill with engine coolant.
18. Fill with cooling fan fluid.
19. Start engine and check for leaks.
20. Install engine under cover.