TIMING BELT INSTALLATION


  1. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. A01DNHUE05

      Install the No. 1 belt idler with the 3 bolts.

      Torque:
      for bolt A
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      for bolt B, C
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips

      A01DMBME03

      • The bolt lengths for bolt A, B and C as follows.

      • Bolt C is combined with the No. 1 timing belt idler.

      Standard Bolt
      Item Length
      A 76.5 mm (3.01 in.)
      B 42.9 mm (1.69 in.)
      C 41.3 mm (1.63 in.)

  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01DRT0E03
      Text in Illustration
      *1 Timing Mark
      A01DQPB Turn

      Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.

      Note

      Do not turn the crankshaft pulley counterclockwise.

    2. A01DTSME01

      Set the timing and drive pulleys at each position.

      Note


      • Make sure the engine is cold.

      • When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.

  3. INSTALL TIMING BELT

    A01DSRWE01

    Tech Tips

    If reusing the timing belt, align the points marked during removal, and install the timing belt with the arrow pointing in the direction the belt moves when the engine is running.


    1. Remove any oil or water on each pulley, and keep them clean.

    2. Install the timing belt to the crankshaft timing and timing belt idlers.

    3. A01DN6GE01
      Text in Illustration
      *1 Timing Mark

      Using SST, slightly turn the injection pump drive pulley clockwise. Install the timing belt to the pulley, and align the timing marks of the drive pulley and timing belt case.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    4. A01DRUIE01
      Text in Illustration
      *1 Timing Mark

      Using SST, slightly turn the camshaft timing pulley clockwise. Install the timing belt to the timing pulley, and align the timing marks of the timing pulley and timing belt case.

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

    5. Check that the timing belt has tension between the injection pump drive and camshaft timing pulleys.

    6. Install the timing belt to the No. 1 timing belt idler.

    7. A01DPGUE01

      Loosen the No. 1 timing belt idler bolt (A), and stretch the timing belt.

    8. Slowly turn the crankshaft pulley.

      Note

      Always turn the crankshaft clockwise.

    9. Tighten the No. 1 timing belt idler bolt.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  4. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

      Note

      Always turn the crankshaft clockwise.

    2. A01DULV

      Check that the timing marks for each pulley align as shown in the illustration.

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

  5. INSTALL TIMING BELT GUIDE


    1. A01DPW3E01

      Install the timing belt guide with the cup side facing outward.

  6. INSTALL TIMING BELT COVER


    1. A01DM71E02
      Text in Illustration
      *1 Gasket

      Install 2 new gaskets to the timing belt cover.

    2. A01DN4HE01

      Install the timing belt cover with the 11 bolts and washers.

      Torque:
      for bolt A
      8.5 N*m  { 85 kgf*cm, 75 ft.*lbf }
      except bolt A
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  7. INSTALL IDLE PULLEY ASSEMBLY


    1. Install the idle pulley bracket with the 2 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  8. INSTALL CRANKSHAFT PULLEY


    1. Align the key groove of the pulley with the pulley set key, and slide the pulley onto the crankshaft to install it.

    2. A01DOQRE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      235 N*m  { 2396 kgf*cm, 173 ft.*lbf }

  9. INSTALL VANE PUMP DRIVE PULLEY


    1. Install the vane pump drive pulley and cooler compressor drive pulley with the 4 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  10. INSTALL FAN SHROUD


    1. Install the fan shroud Click here.

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  12. INSPECT ENGINE IDLE SPEED


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Idle speed
        720 to 820 rpm

        Note


        • Turn all the electrical systems and the A/C off.

        • When checking the idling speed, the shift lever should be in neutral.

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

    3. A01DR2AE08
      Text in Illustration
      *a Front View of DLC3

      When not using an intelligent tester:


      1. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18040

      2. Check the idle speed.

        Standard idle speed
        720 to 820 rpm

        Note


        • Turn all the electrical systems and the A/C off.

        • When checking the idling speed, the shift lever should be in neutral.

        • Confirm the terminal number before connecting them. Connecting the wrong terminal can be damage the engine.

  13. INSPECT MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Check the maximum speed.

      Maximum engine speed
      4850 to 4950 rpm