Hydraulic Body

REMOVAL
1. Remove engine under cover.
2. Drain engine coolant.
3. Remove air cleaner duct.
4. Remove drive belt, fan, fluid coupling assembly and water pump pulley as follows:

(a) Loosen the 4 nuts holding the fluid coupling to the water pump.

(b) Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt.
(c) Remove the 4 nuts, the fan, fluid coupling assembly and water pump pulley.
5. Remove radiator assembly as described under Cooling System.

6. Remove power steering pump pulley and front bracket as follows:
(a) Using the variable pin wrench Special Service Tool (SST) No. 09962-01000 with pins tool (SST) No. 09963-01000 installed, or equivalent, remove the nut and pulley.
(b) Remove the 3 bolts, plate washer and pump front bracket.

7. Remove No. 3 timing belt cover as follows:
(a) Remove the oil filler cap.
(b) Using a 5 mm hexagon wrench, remove the 6 bolts and belt cover.

8. Using a 5 mm hexagon wrench, remove the 3 bolts, belt cover and gasket, then remove No. 2 timing belt cover.

9. Remove the 3 drive belt tensioner bolts, then the tensioner

10. Set No. 1 cylinder to TDC/compression as follows:
(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No. 1 timing belt cover.

NOTE: Always turn the crankshaft clockwise.

(b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover.
(c) If not, turn the crankshaft 1 revolution (360°).
11. Remove timing belt from camshaft timing pulleys as follows:

NOTE: If re-using timing belt, place matchmarks on the timing belt and camshaft timing pulleys as shown in the illustration.

(a) Alternately loosen then remove the 2 tensioner bolts, then the tensioner and dust boot.

INSTALLATION
1. Install crankshaft timing pulley as follows:

(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley facing the flange side inward.

NOTE: Do not scratch the sensor part of the crankshaft timing pulley.

(c) Install the timing belt plate with the bolt, tighten to 7.8 Nm (69 inch lbs.).
2. Install idler pulley as follows:

(a) Apply LOCTITE 242, or equivalent, adhesive to 2 or 3 threads of the pivot bolt.
(b) Using a suitable 10 mm hexagon wrench, install the plate washer and pulley with the pivot bolt, then tighten to 34 Nm (25 ft. lbs.).
(c) Check that the pulley bracket moves smoothly.

3. Temporarily install the crankshaft pulley bolt, then proceed as follows:
(a) Use the bolt to turn the crankshaft and align the timing marks on the crankshaft timing pulley and on the oil pump body.

NOTE: The engine should be cold.

(b) Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.

(c) Install the timing belt on the crankshaft timing pulley and idler pulley.

NOTE: When re-using timing belt align the match marks (made on removal) of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.

4. Install the timing belt guide, facing the cup side outward.
5. Install No. 1 timing belt cover as follows:
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the 5 bolts.
6. Install crankshaft pulley as follows:
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using crankshaft holding Special Service Tool (SST) No 09213-70010 with companion flange holding tool (SST) No. 09330-00021, or equivalents, tighten the pulley bolt to 324 Nm (239 ft. lbs.).
7. Install camshaft timing pulleys as follows:

(a) Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley.
(b) Install the timing pulley bolt hand tight.

(c) Using the variable pin wrench tool (SST) No. 09962-01000 with pins tool (SST) No. 09963-01000 installed, or equivalent, tighten the pulley bolt to 79 Nm (59 ft. lbs.).
8. Align engine timing marks as follows:

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

NOTE: Always turn the crankshaft clockwise.

(b) Using Using the variable pin wrench, align the timing marks of the camshaft timing pulleys and No. 4 timing belt cover.
9. Install timing belt as follows:

NOTE: When re-using timing belt, align the matchmarks (made on removal) of the timing belt and camshaft timing pulleys.

(a) Remove any oil or water on the camshaft timing pulley, and keep it clean.

(b) Install the timing belt, checking the tension between the crankshaft timing pulley and exhaust camshaft timing pulley.
10. Pre-set timing belt tensioner as follows:

(a) Using a press, slowly press in the push rod using 981-9,807 N (220-2,205 lbs.) of force.

(b) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted.
(c) Release the press.
(d) Install the dust boot onto the tensioner.
11. Install timing belt tensioner as follows:

(a) Temporarily install the tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts, tighten to 26 Nm (20 ft. lbs.).