Timing Belt Installation

INSTALLATION OF TIMING BELT

1. Install camshaft timing pulleys.





(a) Position the knock pin of the camshafts as shown in the figure.
(b) Align the camshaft knock pin with the knock pin groove of the pulley, and slide the pulley, facing the timing mark upward.





(c) Secure the hexagonal wrench head portion of the camshaft, and install the plate washer and bolt. Torque the bolt.

Torque: 475 kg-cm (34 ft-lb, 47 N.m)

NOTE:
^ Remove any oil or water on the camshaft timing pulley and keep it clean.
^ Be careful not to damage the cylinder head with the wrench.

2. Install cylinder head covers with gasket.





(a) Apply seal packing to the cylinder head as shown in the figure.

Seal packing: Part No. 08826-00080 or equivalent





(b) Install the intake and exhaust head covers with the gaskets.
(c) Install the center cover with the gasket.
(d) Connect the following wires:
^ Distributor wire connector
^ Engine compartment cooling fan motor connector
^ Oil pressure sender gauge connector
^ Compressor connector (A/C only)
^ Noise filter connector

3. Install PCV hose.





4. Install crankshaft timing pulley.
Install the crankshaft timing pulley and align the TDC marks on the oil pump body and crankshaft timing pulley

NOTE: Remove any oil or water on the crankshaft timing pulley and keep it clean.





5. Temporarily install idler pulley and tension spring.
(a) Install the pulley with the bolt. Do not tighten the bolt yet.
(b) Install the tension spring.
(c) Pry the pulley toward the left as far as it will go and tighten the bolt.





6. Set No.1 cylinder to TDC/Compression.
(a) Align the timing marks of the camshaft timing pulleys and No.4 timing belt cover by turning the camshafts.
(b) Align the timing marks of the crankshaft timing pulley and oil pump body by turning the crankshaft.

7. Install timing belt.

CAUTION: The engine should be cold.





NOTE: If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.





Install the timing belt, insuring the tension between the intake camshaft and crankshaft timing pulleys.
8. Check valve timing and timing belt deflection.





(a) Slowly loosen the idler pulley bolt.





(b) Temporarily install the crankshaft pulley bolt, and turn the crankshaft pulley two revolutions from TDC to TDC.

NOTE: Always turn the crankshaft clockwise.





(c) Check that each pulley aligns with the timing marks as shown in the figure. If the marks do not align, remove the timing belt and reinstall it.





(d) Torque the idler pulley bolt.

Torque: 375 kg-cm (27 ft-lb 37 N.m)





(e) Check that there is belt deflection at the position indicated in the figure.
If the deflection is not as specified, adjust with the idler pulley.

Deflection: 4 mm (0.16 in.) at 2 kg (4.4 lb, 20 N)





(f) Remove the temporarily installed crankshaft pulley bolt.





9. Install timing belt guide.
Install the guide, facing the cup side outward.

10. Install timing belt covers.
(a) Install the gaskets to the belt covers.
(b) Install the No.1, No.2 and No.3 belt cover with the ten bolts.





NOTE: Each bolt length is indicated in the figure.

11. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, slide the pulley.





(b) Using SST 09213-70010 and 09330-00021, install and torque the the bolt.

Torque: 1,400 kg-cm (101 ft-lb, 137 N.m)

12. Temporarily install water pump pulley.
13. Install RH engine mounting insulator.





(a) Install the RH engine mounting insulator to the engine with two nuts.
Align the RH mounting insulator into the bracket and install the mounting through bolt.

Torque:
Nut 530 kg-cm (38 ft-lb, 52 N.m)
Through bolt 890 kg-cm (64 ft-lb, 87 N.m)





(b) Install the RH mounting stay and three bolts, remove the jack.

Torque: 430 kg-cm (31 ft-lb, 42 N.m)





14. Install spark plugs.
Using a plug wrench (16 mm), install the spark plugs.

Torque: 180 kg-cm (13 ft-lb, 18 N.m)





15. Install alternator drive belt and tighten water pump pulley bolt.
(a) Place the drive bolt on to each pulley.
(b) Stretch the belt tight and tighten the four water pump pulley bolts.

16. Install PS and/or A/C drive belt.





17. Adjust drive belt tension.
Using a belt tension gauge, adjust the drive belt tension.

Drive belt tension:
Alternator
New belt 175 ± 5 lb
Used belt 115 ± 20 lb
P/S and/or A/C
New belt 175 ± 5 lb
Used belt 115 ± 20 lb





18. Install water outlet hose.
19. Install washer tank.





20. On vehicles with cruise control, install cruise control actuator.
(a) Install the actuator bracket and two bolts.
(b) Install the actuator and three bolts.
(c) Connect the actuator and vacuum switch connectors.
(d) Connect the vacuum hoses to the actuator and vacuum switch.

21. Connect accelerator cables.
(a) Connect the accelerator cable.
(b) On vehicles with cruise control, connect the cruise control cable.

22. Refill coolant.
23. Start engine and check for leakage.
24. Install engine under cover.
25. Install RH wheel.