Installation

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 to 2 or 3 threads of the pivot bolt.

Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

(b) Using a 1 0 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt.

Torque: 34 N.m (350 kg cm, 25 ft.lb)

(c) Check that the pulley bracket moves smoothly.

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

Torque: 34 N.m (350 kg cm, 25 ft.lb)

(b) Check that the idler pulley moves smoothly.

4. Temporarily install timing belt

NOTE: 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, oil pump pulley, water pump pulley, No.1 idler pulley and 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:
12 mm head: 16 N.m (160 kg cm, 12 ft.lb)
14 mm head: 30 N.m (310 kg cm, 22 ft.lb)

HINT: Each bolt length is indicated in the illustration. Bolt length:
A: 106 mm (4.17 in.)
B: 114 mm (4.49 in.)

(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

(c) Using SST, install the pulley bolt. SST 09950-50010

Torque: 245 N.m (2,500 kg cm, 181 ft.lb)

10. Install right hand 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.

11. Install left hand 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 "L" mark forward.
(c) Using SST, install the pulley bolt. SST 09960-10010

Torque: 108 N.m (1,100 kg cm, 80 ft lb)

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 09960-10010

13. Connect timing belt to left hand camshaft timing pulley

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

(c) Using SST, slightly turn the left hand 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 left hand camshaft timing pulley. SST 09960-10010

(d) Using SST, align the timing marks of the left hand camshaft timing pulley and timing belt rear plate. SST 09960-10010
(e) Check that the timing belt has tension between the crankshaft timing pulley and left hand camshaft timing pulley.

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

(b) Using SST, slightly turn the right hand 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 right hand camshaft timing pulley. SST 09960-10010

(c) Using SST, align the timing marks of the right hand camshaft timing pulley and timing belt rear plate. SST 09960-10010
(d) Check that the timing belt has tension between the right hand camshaft timing pulley and left hand camshaft timing pulley.

15. Set timing belt tensioner
(a) Using a press, slowly press in the push rod using 981 - 9,807 N m (100 - 1.000 kg cm, 220 - 2,205 lb) 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: 26 N.m (270 kg cm, 20 ft lb)

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

NOTE: Always turn the crankshaft pulley clockwise.

(b) Check that each pulley aligns with the timing marks as 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 N.m (180 kg cm, 13 ft.lb)

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

Torque: 16 N.m (160 kg cm, 12 ft.lb)

HINT: Use a 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 N.m (380 kgf.cm, 27 ft.Ibf)

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

21. Install right hand distributor housing
Install the distributor housing with the 3 bolts.

Torque: 18 N.m (185 kg cm. 13 ft.lb)

HINT:
- The right hand distributor housing is marked with "R".
- Each bolt length is indicated in the illustration. Bolt length:
A: 38 mm (1.50 in.)
B: 96 mm (3.78 in.)

22. Install left hand distributor housing
Install the distributor housing with the 3 bolts.

Torque: 18 N.m (185 kg cm, 13 ft.lb)

HINT:
- The left hand distributor housing is marked with "L".
- Each bolt length is indicated in the illustration. Bolt length:
A: 38 mm (1.50 in.)
B: 80 mm (3.15 in.)

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 N.m (39 kg cm, 34 in.lb )

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

Torque: 3.8 N.m (39 kg cm. 34 in.lb)

25. Install right hand 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 (185 kg cm, 13 ft lb)

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) Except Calif.:
Install the camshaft position sensor connector to the ignition coil bracket.

26. Install left hand 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 N.m (380 kg cm 27 ft lb)

28. Install high-tension cords, cord clamps and cord cover assembly
(a) Connect the high-tension cords to the spark plugs distributor caps and right hand ignition coil.
(b) Install the lower high-tension cord cover with the bolt.
(c) Connect the right hand front high-tension cord clamp to the lower high-tension cord cover.
(d) Place the right hand front high-tension cord clamp to the right hand rear high-tension cord clamp.

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

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

29. Install right hand 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.

(d) Connect the 2 air control valve hoses.

30. Install left hand 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 left hand 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.

31. Install right hand 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.

32. Install left hand engine wire cover
(a) 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.

33. 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.

34. Install left hand 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

35. 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

36. Install air conditioning (a/c) ccompressor

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

Torque: Bolt: 49 N.m (500 kgf.cm, 36 ft.lbf)
Torque: Nut: 29 N.m (300 kgf.cm, 22 ft.Ibf)

(b) Connect the A/C compressor connector.

37. 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 and screw. Install the 2 upper radiator supports.

Torque: 12 N.m (120 kg cm, 9 ft lb)

(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.

38. 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 N.m (50 kg cm, 43 in lb)

(c) Connect the following hoses:
(1) Reservoir hose to water inlet housing
(2) Reservoir hose to radiator

(d) Connect the coolant level sensor connector.

39. Install drive belt
Install the drive belt by turning the drive belt tensioner counterclockwise.

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

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