Installation
INSTALLATION STEPS
SERVICE POINTS OF INSTALLATION
36. Installation of crankshaft sprocket " B."
Install the crankshaft sprocket "B" as shown while paying attention to its direction.
35. Installation of spacer.
(1) Apply a thin coat of engine oil to the outer circumference of the spacer.
(2) Install the spacer with the chamfered end facing the oil seal.
NOTE: If the spacer is installed adversely, the oil seal may be damaged, resulting in the oil leaks.
33. Installation of timing belt " B."
(1) Ensure that crankshaft sprocket "B" timing mark and the silent shaft sprocket timing mark are aligned.
(2) Fit timing belt "B" over crankshaft sprocket "B" and the silent shaft sprocket. Ensure that there is no slack in the belt.
- Adjustment of timing belt "B" tension.
(1) Temporarily fix the timing belt "B" tensioner such that the center of the tensioner pulley is to the left and above the center of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.
(2) Holding the timing belt "B" tensioner up with your finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner.
Caution: When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.
(3) To ensure that the tension is correct, depress the belt (point A) with a finger. If not, adjust.
Standard value: 5-7 mm (0.20-0.28 in.).
31. Installation of flange.
Install the flange in correct direction as shown.
Caution: Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken timing belt could result.
30. Installation of crankshaft sprocket.
Install the crankshaft sprocket in the correct direction as shown.
Caution: Pay special attention to the direction of the flange. If it is installed in the wrong direction a broken timing belt could result.
27. Installation of oil pump sprocket.
(1) Insert a Phillips screwdriver [shank diameter 8 mm (0.31 in.) shaft] through the plug hole on the left side of cylinder block to block the left silent shaft.
(2) Install the oil pump sprocket.
(3) Tighten the nut to the specified torque.
26. Installation of camshaft sprockets.
Using a wrench hold the camshaft at its hexagon (between the No.2 and No.3 journals) and tighten the bolt to specification.
Caution: Locking the camshaft sprocket with a tool damages the sprocket.
21. Installation of auto tensioner.
(a) If the auto tensioner rod is in its fully extended position, reset it as follows.
(1) Keep the auto tensioner level and, in that position, clamp it in the vise with soft jaws.
If the plug at the bottom of the auto tensioner protrudes, surround it with a plain washer as illustrated to prevent the plug from being in direct contact with the vise.
(2) Push in the rod little by little with the vise until the set hole (A) in the rod is aligned with that (B) in the cylinder.
(3) Insert a wire [1.4 mm (0.055 in.) in diameter] into the set holes.
(4) Unclamp the auto tensioner from the vise.
(b) Install the auto tensioner.
Caution: Leave the wire installed in the auto tensioner.
23. Installation of tensioner pulley.
(1) Install the tensioner pulley onto the tensioner arm.
(2) Locate the pinhole in the tensioner pulley shaft to the left of the center bolt. Then, tighten the center bolt finger-tight.
Caution: Leave the wire installed in the auto tensioner.
22. Installation of timing belt.
(1) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate one tooth in the counterclockwise direction. This should be taken into account when installing the timing belt on the sprockets.
NOTE: The same camshaft sprocket is used for the intake and exhaust camshafts and is provided with two timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the one on the left with the dowel pin hole on top.
(2) Align the crankshaft sprocket timing mark.
(3) Align the oil pump sprocket timing mark.
(4) Insert a Phillips screwdriver [shank diameter 8 mm (0.31 in.)] through the hole. If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned. If the inserted depth is only 20-25 mm (0.8-1.0 in.), turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm (2.4 in.) or more. Keep the screwdriver inserted until the installation of the timing belt is finished.
NOTE: Step (4) is performed to ensure that the oil pump sprocket is correctly positioned with reference to the silent shafts.
(5) Thread the timing belt over the intake side camshaft sprocket and fix it an indicated position by a clip.
(6) Thread the timing belt over the exhaust side sprocket. aligning the timing marks with the cylinder head top surface using two wrenches.
(7) Fix the belt at indicated position by a clip.
(8) Thread the timing belt over the idler pulley, the oil pump sprocket the crankshaft sprocket and the tension pulley in the order shown.
(9) Remove the two clips.
(10) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt.
(11) Check to see that all timing marks are lined up.
(12) Remove the screwdriver inserted in step (4) and fit the plug.
(13) Give the crankshaft a quarter counterclockwise turn. Then, turn it clockwise until the timing marks are lined up again.
- Adjustment of timing belt tension.
(1) After turning the crankshaft 1/4 turn counterclockwise, turn it clockwise to move the No.1 cylinder to top dead center.
(2) Loosen the center bolt, and then, as shown in the illustration, attach the special tool and a torque wrench and apply a torque of 2.6-2.8 Nm (1.88-2.03 ft.lbs.). it the body interferes with the special tool and the torque wrench, use a jack to slightly raise the engine assembly.
NOTE: Use a torque wrench that is capable of measurement within a range of 0-3 Nm (0-2.2 ft.lbs.).
(3) Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification.
(4) Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At that point, screw the special tool in some more and then remove the set wire attached to the auto tensioner.
(5) Remove the special tool.
(6) Rotate the crankshaft two complete turns clockwise and leave it as is for about 15 minutes. Then, measure the auto tensioner protrusion "A" (distance between the tensioner arm and auto tensioner body) to ensure that it is up to specification.
Standard value: 3.8-4.5 mm (0.15-0.18 in.).
If it is out of specification, repeat steps (6) through (1) until the specified value is obtained.
(7) If the clearance between the tensioner arm and the auto tensioner body cannot be measured (when the engine is being mounted, etc.), the following procedures can be used to substitute for the ordinary method of measurement.
(1) Screw in the special tool until it contacts the tensioner arm.
(2) From that point of contact. further screw in the special tool, screwing it in until the push rod of the auto tensioner body is caused to move backward and the tensioner arm contacts the auto tensioner body. Check to be sure that the amount that the special tool has been screwed in (when the push rod moves backward) is the standard value.
Standard value: 2.5-3 turns.
(8) Install the rubber plug to the timing belt rear cover.
13. Installation of timing belt lower cover/12.Timing belt upper cover.
The dimensions of the installation bolts for the timing covers differ according to the installation location, so be sure not to install the bolts in the incorrect locations.
SEALING POINTS
Post-installation 0peration.
- Installation of under cover.
- Engine adjustment.