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.).
(c) Remove the 1.5 mm hexagon wrench from the tensioner with pliers.
12. Check valve timing as follows:
(a) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTE: Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as shown in the illustration.
NOTE: If the marks do not align, remove the timing belt and reinstall it.
13. Install drive belt tensioner, tighten to 21 Nm (15 ft. lbs.).
NOTE: Be careful not to drop the bolts inside the timing belt cover.
14. Install no. 2 timing belt cover.
15. Install no. 3 timing belt cover.
16. Install power steering pump front bracket and pump pulley as follows:
(a) Install the pump front bracket with the 2 bolts, (A) in illustration, hand tight.
(b) Install the plate washer and bolt, (B) in illustration, and tighten the 2 bolts (A).
(c) Tighten to:
Bolt (A) 58 Nm (43 ft. lbs.).
Bolt (B) 52 Nm (38 ft. lbs.).
(d) Install the pump pulley with the nut hand tight.
(e) Using the variable pin wrench to hold pulley, tighten the pulley nut to 43 Nm (32 ft. lbs.).
17. Install radiator assembly, refer to cooling system.
18. Install water pump pulley, fan, fluid coupling assembly and drive belt.
19. Install air cleaner duct.
20. Fill engine with coolant.
21. Check automatic transmission fluid level.
22. Start engine check for leaks.
23. Install engine under cover.
24. Road test, check for abnormal noise, shock, slippage, correct shift points and smooth operation.
25. Recheck engine coolant level.