INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley facing the flange side inward.
NOTICE:
Do not scratch the sensor part of the crankshaft timing
pulley.
(c) Install the timing belt plate with the bolt.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
2. INSTALL IDLER PULLEY
(a) Apply adhesive to 2 or 3 threads of the pivot bolt.
(Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent)
(b) Using a 10 mm hexagon wrench, install the plate washer
and pulley with the pivot bolt.
Torque: 35 N·m (350 kgf·cm, 26 ft·lbf)
(c) Check that the pulley bracket moves smoothly.
3. TEMPORARILY INSTALL TIMING BELT
NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft, and
align the timing marks on the crankshaft timing pulley and
on the oil pump body.
(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.
HINT: (When re–using timing belt):
Align the match marks of the crankshaft timing pulley and timing
belt, and install the belt with the arrow pointing in the direction
of engine revolution.
4. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
5. INSTALL NO.1 TIMING BELT COVER
6. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) install the bolt.
Torque: 330 N·m (3,300 kgf·cm, 243 ft·lbf)
7. A/T: CONNECT OIL COOLER TUBES
8. INSTALL CAMSHAFT TIMING PULLEYS
(a) Align the camshaft knock pin with the groove of the pulley,
and slide on the timing pulley.
(b) Temporarily install the timing pulley bolt.
(c) tighten the pulley bolt.
Torque: 81 N·m (810 kgf·cm, 60 ft·lbf)
9. 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.
NOTICE: Always turn the crankshaft clockwise.
(b) align the timing marks of the camshaft timing
pulleys and No.4 timing belt cover.
10. INSTALL TIMING BELT
HINT: (When re–using timing belt):
Align the matchmarks 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.
11. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 981 –
9,807 N (100 – 1,000 kgf, 220 – 2,205 lbf) 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.
12. INSTALL TIMING BELT TENSIONER
(a) Temporarily install the tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)(c) Remove the 1.5 mm hexagon wrench from the tensioner.
13. CHECK VALVE TIMING
(a) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
14. INSTALL DRIVE BELT TENSIONER
Install the tensioner with the 3 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)NOTICE: Be careful not to drop the bolts inside the timing belt cover.
15. INSTALL NO.2 TIMING BELT COVER
16. INSTALL NO.3 TIMING BELT COVER
17. INSTALL PS PUMP
(a) Temporarily install the pump pulley with the nut.
(b) tighten the pulley nut.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
18. INSTALL WATER PUMP PULLEY, FAN, FLUID COUPLING ASSEMBLY AND DRIVE BELT
INSTALL WATER PUMP
Refer to Diagram
http://i31.tinypic.com/2gtc3dt.jpg
^ Diagram, may need to zoom in using browsers zoom ( CTRL +, use CTRL - to zoom back out)
(a) Install a new O–ring to the cylinder block.
(b) Install the drain hose.
(c) Install a new gasket to the water pump.
(d) Connect the water pump to the water bypass pipe. Do not
install the nut yet.
(e) Install the water pump with the 2 bolts (A) and 4 bolts (B).
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)HINT: Hand tighten the (A) bolts first.
(f) Install the 2 nuts holding the No.2 water bypass pipe to
the water pump.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)(g) Connect the No.3 turbo water hose to the water pump.
INSTALL NO.1 WATER BYPASS PIPE AND
WATER OUTLET
(a) Install 2 new O–rings to the No.1 water bypass pipe.
(b) Apply soapy water to the O–rings.
(c) Install the No.1 water bypass pipe to the water pump.
(d) Install a new gasket and the water outlet with the 2 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)(e) Connect the ECT sensor and sender gauge connectors.
4. CONNECT TURBO WATER HOSES TO WATER OUTLET
5. INSTALL WATER PUMP PULLEY, FAN, FLUID
COUPLING ASSEMBLY AND DRIVE BELT
(a) Align the matchmarks, and install the water pump pulley,
the fan and fluid coupling assembly with the 4 nuts.
(b) Install the drive belt by turning the drive belt tensioner
clockwise.
(c) Stretch the belt tight, and tighten the 4 nuts.
Torque: 16 N·m (165 kgf·cm, 12 ft·lbf)
6. M/T:
INSTALL DRIVE BELT TENSIONER DAMPER
7. ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
19. M/T:
INSTALL DRIVE BELT TENSIONER DAMPER
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
20. INSTALL RADIATOR ASSEMBLY
21. ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
