WATER PUMP INSTALLATION

INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket, the water pump and tension spring bracket with the 6 bolts.
  
  Torque:
  
  23 N*m { 230 kgf*cm, 17 ft.*lbf }
INSTALL TIMING BELT

SST

09960-10010 ( 09962-01000, 09963-01000 )
SET NO.1 CYLINDER TO TDC/COMPRESSION
1. Using the crankshaft pulley bolt, align its groove with the timing pointer by turning the crankshaft clockwise.
  
  Note
  
  Do not turn the crankshaft pulley counterclockwise.
2. Set the timing and drive pulleys at each position.
  Note
  
  The engine should be cold.
  
  When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.
INSTALL TIMING BELT GUIDE
1. Install the belt guide with the cup side facing outward.
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
1. Remove the 2 nuts and wire harness clamp bracket.
2. Install the 2 gaskets to the timing belt cover.
3. Install the timing belt cover with the 11 bolts.
  
  Torque:
  
  11 N*m { 105 kgf*cm, 8 ft.*lbf }
4. Install the 2 nuts and wire harness clamp bracket.
INSTALL CRANKSHAFT PULLEY

SST

09213-54015 ( 91651-60855 )

09330-00021
INSTALL VANE PUMP PULLEY
1. Using SST, install the vane pump pulley to the vane pump assembly.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
  
  Torque:
  
  43 N*m { 439 kgf*cm, 32 ft.*lbf }
INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Temporarily install the compressor mounting bracket with the 4 bolts.
2. Using several steps, uniformly install and tighten the 4 bolts in the sequence shown in the illustration.
  
  Torque:
  
  85 N*m { 870 kgf*cm, 63 ft.*lbf }
3. Temporarily tighten the bolt and spacer.
4. Temporarily install the compressor mounting bracket with the 3 bolts.
5. Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.
  
  Torque:
  
  47 N*m { 475 kgf*cm, 36 ft.*lbf }
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
1. Install the compressor and magnetic clutch with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning)
1. Install the V belt.
2. Using a bar, adjust the tension of the V belt.
3. Tighten the bolts A and B.
  
  Torque:
  
  Bolt A
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
  
  Bolt B
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning System)
1. Install the V belt.
2. Tightening the bolt C, adjust the tension of the V belt.
3. Tighten the bolts A and B.
  
  Torque:
  
  Bolt A
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
  
  Bolt B
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
1. Install the V belt.
2. Tightening the bolt B, adjust the tension of the V belt.
3. Tighten nut A.
  
  Torque:
  
  39 N*m { 400 kgf*cm, 29 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL VANE PUMP V BELT (w/ Air Conditioning System)
1. Install the V belt.
2. Using a bar, adjust the tension of the V-ribbed belt.
3. Tighten the bolt A and nut B.
  
  Torque:
  
  Bolt (A)
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  
  Nut (B)
  
  64 N*m { 635 kgf*cm, 47 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL WATER PUMP PULLEY
CONNECT RADIATOR HOSE NO.4
CONNECT RADIATOR HOSE INLET
ADD ENGINE COOLANT
1. Close the engine drain plug.
  
  Torque:
  
  57 N*m { 581 kgf*cm, 42 ft.*lbf }
2. Close the radiator drain cock plug.
3. Slowly fill the cooling system with coolant.
  
  Tech Tips
  
  The coolant level inside the radiator should be abserved after pressing the radiator hose inlet and radiator hose outlet by hand..
4. Slowly pour coolant into the radiator reserve tank until it reaches the FULL line.
5. Install the radiator cap to the radiator reserve tank.
6. Press the inlet and outlet radiator hoses several times by hand while warming up the engine.
7. Stop the engine, and wait until the engine coolant cools down.
8. Add coolant to the FULL line of the radiator reservoir.
START THE ENGINE
CHECK FOR ENGINE COOLANT LEAKS
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the 5 bolts and engine service hole cover.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH
INSTALL FRONT SEAT ASSEMBLY RH
1. Connect the front seat inner belt assembly connector and install the front seat assembly.
2. Align the front seat assembly adjuster pin with the holes in the body.
3. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.
5. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.
7. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
9. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }