Timing Belt: Installation

1. Align the pulley set key with the key groove of the pulley.
2. Slide on the timing pulley facing the flange side inward.
   NOTE: Do not scratch the sensor part of the crankshaft timing pulley.
   Fig 1: Aligning Pulley Set Key With Key Groove Of Pulley

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3. Install the timing belt plate with the bolt.

   Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

   Fig 2: Installing Timing Belt Plate & Bolt

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1. Apply adhesive to 2 or 3 threads of the pivot bolt.

   Adhesive: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. 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) 

3. Check that the pulley bracket moves smoothly.
   Fig 3: Installing Idler Pulley Bolt Applying Adhesive To Bolt Threads

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1. Use the crankshaft pulley bolt to turn the crankshaft, and align the dot mark on the crankshaft timing pulley and the timing mark on the oil pump body.
2. Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.
   Fig 4: Locating Timing Mark And Dot Mark

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3. Install the timing belt on the crankshaft timing pulley and idler pulley.

   HINT:

   When re-using timing belt:

   Align the matchmarks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.

   Fig 5: Locating Timing Belt Marked Arrow

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Install the guide, facing the cup side outward.

Fig 6: Installing Timing Belt Guide Facing Cup Side Outward

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1. Install the gasket to the timing belt cover.
2. Install the timing belt cover with the 5 bolts.

   Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Check that the sub timing mark (60° mark BTDC) of the crankshaft pulley is aligned with the timing mark "0" of the No. 1 timing belt cover.

   HINT:

   At this time, the crankshaft pulley set key groove and the timing mark (TDC mark) of the crankshaft pulley are as shown.

3. Temporarily install the pulley bolt.
   Fig 7: Installing Crankshaft Pulley

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1. Align the camshaft knock pin with the VVT-i pulley, and push the VVT-i pulley by hand until you feel it touch the bottom.
   Fig 8: Installing VVT-i (Intake Camshaft Timing) Pulley (1 Of 3)

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2. Check that the outer circumference of the VVT-i pulley easily rotates through 30°.
   Fig 9: Installing VVT-i (Intake Camshaft Timing) Pulley (2 Of 3)

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3. Holding the hexagon portion of the camshaft with a wrench.
   Fig 10: Installing VVT-i (Intake Camshaft Timing) Pulley (3 Of 3)

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4. Using a 10 mm hexagon wrench, and the set bolt.

   Torque: 81 N.m (810 kgf.cm, 60 ft.lbf) 

5. Using a 14 mm hexagon wrench, install the straight screw plug with the seal washer to the set bolt.

   Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

6. Align the dot mark on the camshaft timing pulley with the timing mark of the No. 4 timing belt cover.
7. Remove the wrench.

1. Install the union bolt to the oil control valve filter.
   NOTE: In case of touching the filter, avoid holding the mesh part and holding the frame part.
2. Install the oil pipe with 2 new gasket and the union bolt to the No. 3 camshaft bearing cap.

   Torque: 55 N.m (550 kgf.cm, 41 ft.lbf) 

Fig 11: Identifying Union Bolt Mesh Part And Frame Part

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1. Install the cylinder head and gasket with the 6 bolts and 2 nuts.

   Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf) 

2. Install the high-tension cords and clamps with the 2 bolts.

   Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

3. Using a 5 mm hexagon wrench, install the engine wire protector with the bolt and nut.

Fig 12: Installing No. 1 Cylinder Head Cover

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Install the engine cover with the 4 nuts.

1. Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley.
2. Slide the timing pulley on the camshaft, facing the front mark forward.
3. Using SST, install the pulley bolt.

   SST 09960-10010 (09962-01000, 09963-01000)

   Torque: 81 N.m (810 kgf.cm, 60 ft.lbf) 

   Fig 13: Installing Exhaust Camshaft Timing Pulley (1 Of 2)

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4. Using SST, align the dot mark on the camshaft timing pulley with the timing mark of the No. 4 timing belt cover.

   SST 09960-10010 (09962-01000, 09963-01000)

   Fig 14: Installing Exhaust Camshaft Timing Pulley (2 Of 2)

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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.

• Align the matchmarks of the timing belt and camshaft timing pulleys.
  Fig 15: Placing Matchmarks On Timing Belt And Camshaft Timing Pulleys

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1. Remove any oil or water on the camshaft timing pulley, and keep it clean.
2. Install the timing belt, checking the tension between the crankshaft timing pulley and intake camshaft timing pulley.
   Fig 16: Installing Timing Belt

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1. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of force.
2. 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.
3. Release the press.
   Fig 17: Aligning Push Rod And Housing Holes

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4. Install the dust boot onto the tensioner.
   Fig 18: Installing Dust Boot Onto Tensioner

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1. Temporarily install the tensioner with the 2 bolts.
2. Alternately tighten the 2 bolts.

   Torque: 27 N.m (270 kgf.cm, 20 ft.lbf) 

   Fig 19: Installing Timing Belt Tensioner

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3. Remove the 1.5 mm hexagon wrench from the tensioner with pliers.
   Fig 20: Removing Hexagon Wrench From Tensioner

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1. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
   NOTE: Always turn the crankshaft clockwise.
   Fig 21: Checking Valve Timing

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2. Check that each pulley aligns with the timing marks as shown.

   If the marks do not align, remove the timing belt and reinstall it.

   Fig 22: Aligning Match Marks

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Using SST, install the pulley bolt.

SST 09213-7001 1, 09330-00021

Torque: 330 N.m (3,300 kgf.cm, 243 ft.lbf)

Install the tensioner with the 3 bolts.

Fig 23: Installing Drive Belt Tensioner

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Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 

1. Install the gasket on the timing belt cover.
2. Using a 5 mm hexagon wrench, install the timing belt cover with the 3 bolts.

   Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

1. Install the gasket on the timing belt cover.
2. Using a 5 mm hexagon wrench, install the timing belt cover with the 4 bolts.

   Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

3. Install the oil filler cap.

1. Temporarily install the vane pump to the bracket.
2. Install the plate washer and front bracket with the 3 bolts.

   Torque: 58 N.m (590 kgf.cm, 43 ft.lbf) for A bolts 

   52 N.m (530 kgf.cm, 38 ft.lbf) for B bolt 

Fig 24: Installing PS Pump And Front Bracket Bolts

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Check for abnormal noise, shock, slippage, correct shift points and smooth operation.