Installation
Components For Timing Belt System Removal And Installation (Part 1 Of 4):
Components For Timing Belt System Removal And Installation (Part 2 Of 4):
Components For Timing Belt System Removal And Installation (Part 3 Of 4):
Components For Timing Belt System Removal And Installation (Part 4 Of 4):
1. Set timing belt tensioner for installation as follows:
(a) Using a press, slowly press in the push rod using do not exceed 981-9,807 N (100-1,000 kg, 220-2,205 lbs.) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon (Allen) 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.
2. Install timing belt tensioner as follows:
(a) Install the belt tensioner with the two bolts hand tight.
(b) Alternately tighten the two bolts, final tighten to 26 Nm (270 kg cm, 19 ft.lb).
(c) Using pliers, remove the 1.27 mm hexagon (Allen) wrench from the belt tensioner.
3. Check valve timing as follows:
(a) Install the crankshaft pulley bolt hand tight.
(b) Slowly turn the crankshaft pulley in a clockwise direction two revolutions from TDC to TDC.
NOTE: Always turn the crankshaft pulley clockwise.
(c) Check that each pulley aligns with the timing marks as shown in the illustrations.
(d) If the timing marks do not align, remove the timing belt and reinstall it.
4. Using crankshaft pulley holder Special Service Tool (SST) No. 09213-54015 and companion flange holder SST No. 09330-00021, or equivalent, tighten the pulley bolt to 245 Nm (2,500 kg.cm, 181 ft.lb).
5. Install the fan bracket with the two bolts and two nuts positioned as shown in the illustration, tighten as follows:
106 mm (4.17 in) for 12 mm head (A) 16 Nm (160 kg.cm, 12 ft.lb).
114 mm (4.49 in) for 14 mm head (B) 32 Nm (330 kg.cm, 24 ft.lb).
NOTE: Each bolt length is indicated in the illustration.
6. (a) Install the A/C compressor, compressor stay and wire bracket with the three bolts and nut, tighten bolts to 49 Nm (500 kg.cm, 36 ft.lb), the nut to 29 Nm (300 kg.cm, 22 ft.lb), then connect the following components:
- Ground cable to the compressor stay with the bolt.
- Wire clamp to the bracket on the A/C compressor.
- A/C compressor connector.
7. Install No.1 ignition coil, refer to Powertrain Management.
8. Install distributor housings, refer to Powertrain Management.
9. Install RH No.2 timing belt cover as follows:
(a) Install the four 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 fan bracket.
(d) Fit the timing belt cover holes, matching them with the two grommets on the distributor.
(e) Install the timing belt cover with the four bolts, tighten 12 mm x 106 mm (4.170 in) in length bolts to 16 Nm (160 kg.cm, 12 ft.lb).
(f) Install the No.2 camshaft position sensor wire to the wire clamp on the timing belt cover.
(g) Install the wire clamp to the timing belt cover.
(h) Install the sensor connector to the ignition coil bracket.
(i) Install the radiator reservoir outlet pipe to the RH cylinder head and timing belt cover with the two bolts.
(j) Connect the outlet hose to the water inlet housing.
10. Install LH No.2 timing belt cover as follows:
(a) Install the two gaskets to the timing belt cover.
(b) Run the No.1 camshaft position sensor wire through the timing belt cover hole.
(c) Fit the timing belt cover, matching it with the fan bracket.
(d) Fit the timing belt cover holes, matching them with the two grommets on the distributor.
(f) Install the timing belt cover and connector bracket with the three bolts.
(g) Install the wire grommet to the timing belt cover.
(h) Install the sensor connector to the connector bracket. Connect the sensor connector.
(i) Install the sensor wire to the wire clamp on the timing belt cover.
(j) Install the engine wire to the two wire clamps on the timing belt cover.
11. Install the drive belt idler pulley and cover plate with the bolt, tighten to 37 Nm (380 kg.cm, 27 ft.lb).
12. Install RH No.3 timing belt cover as follows:
(a) Install the two 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 four bolts.
(d) Install the two air control valve hoses of the PS pump to the hose clamp on the timing belt cover.
13. Install LH No.3 timing belt cover as follows:
(a) Install the two 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 four bolts.
(f) Install the EVAP hose clamp to the timing belt cover.
14. Install radiator assembly as follows:
(a) Install the two lower radiator supports to the radiator.
(b) Place the radiator assembly on the body bracket.
(c) Install the radiator with the two upper radiator supports and two nuts, tighten to 13.5 Nm (135 kg.cm, 10 ft.lb).
(d) Install the upper sides of the RH and LH cool air ducts.
(e) Connect the ECT switch connector for the A/C cooling fan.
NOTE: After installation, check that the rubber cushion (A) of the support is depressed.
(f) Connect the claw of the No.2 fan shroud to the hook of the No.1 fan shroud, then install the two clips.
(g) Connect these hoses to the radiator:
- Upper radiator hose.
- Lower radiator hose.
- The two A/T oil cooler hoses.
- Radiator reservoir hose.
15. Install fan pulley, fan, fluid coupling and drive belt as follows:
(a) Install the fan pulley, the fan, fluid coupling assembly with the four nuts hand tight.
(b) Install the drive belt.
(c) Tighten the four nuts holding the fluid coupling to the fan bracket to 21 Nm (215 kg.cm, 16 ft.lb).
16. Install air cleaner and intake air connector assembly.
17. Install V-bank cover.
18. Fill with engine coolant.
19. Start engine and check for leaks.
20. Check engine coolant level.
21. Install air cleaner inlet.
22. Install battery clamp cover.
23. Install engine under cover.
24. Install oil pan protector.