1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the pulley.
(b) Using SST, install the nut.
2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the flange side inward.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the pulley with the bolt. Torque: 425 kg-cm (31 ft-lb, 42 Nm) HINT: Use bolt 35 mm (1.38 in.) in length,
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
(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.
(d) Check that the idler pulley moves smoothly.
5. TEMPORARILY INSTALL TIMING BELT
NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft and position the key groove of the crankshaft timing pulley upward.
(b) Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley, No.2 idler pulley, and keep them clean.
(c) Install the timing belt on the crankshaft timing, oil pump pulley, No.2 idler pulley, water pump pulley and No.2 idler pulley.
HINT (When re-using timing belt): Align the match-marks of the camshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.
INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the four bolts.
INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, slide on the pulley.
(b) Using SST, install the pulley bolt.
INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the timing pulley.
HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).
10. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
(b) Using SST, turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap.
11. INSTALL TIMING BELT
HINT (When re-using timing belt): • Check that the matchmark on the timing belt matches the end of the No.1 timing belt cover.
If the matchmark does not align, shift the meshing of the timing belt and crankshaft timing pulley until they align. (See page EM-51)
• Align the matchmarks of the timing belt and camshaft timing pulley.
(a) Remove any oil or water on the camshaft timing pulley, and keep it clean.
(b) Install the timing belt, insure that there is tension between the crankshaft timing pulley and camshaft timing pulley.
12. CHECK VALVE TIMING
(a) Loosen the No.1 idler pulley bolt 1/2 turn.
(b) Turn the crankshaft pulley two revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft clockwise.
(c) Check that each pulley aligns with the timing marks as shown in the figure.
If the timing marks do not align, remove the timing belt and reinstall it.
(d) Torque the mount bolt of the No.1 idler pulley. Torque: 425 kg-cm (31 ft-lb, 42 N m)
13. INSTALL SPARK PLUGS (See page IG-12) Torque: 180 kg-cm (13 ft-lb, 18 Nm)
14. INSTALL NO.2 TIMING BELT COVER
(a) Install the two gaskets to the No.1 and No.2 belt covers.
(b) Install the belt cover with the five bolts.
(c) Install the two clamps of the engine wire to each bolt.
15. INSTALL RH ENGINE MOUNTING BRACKET
Install the bracket with the three bolts.
HINT: Lower the jack and perform the operation with the engine fully up.
16. INSTALL RH ENGINE MOUNTING INSULATOR
Install the mounting insulator with the through bolt and two nuts.
17. INSTALL RH ENGINE MOUNTING STAY
Install the mounting stay with the bolt and nut. Torque: 740 kg-cm (54 ft-lb, 73 N-m)
18. INSTALL ALTERNATOR DRIVE BELT
Install the drive belt with the adjusting bolt, lock bolt and pivot bolt.
19. INSTALL A/C DRIVE BELT
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