33. Install the timing pulley on the camshaft (if it was removed), with the flange side facing out. Align the pin hole in the toothed pulley with the pin on the end of the camshaft. Do not mix up the toothed pulleys of the camshafts. Install the toothed pulley of the intake camshaft on the intake shaft and the toothed pulley of the exhaust camshaft on the exhaust shaft.
34. Screw in the camshaft toothed pulley mounting bolt and tighten it(them) to the prescribed torque specified in Specifications at the beginning of this chapter.
35. Install the tensioner pulley. Apply thread locking compound to the first two or three threads of the bolt, then install the pulley and washer and screw in the bolt. Tighten the bolt to the specified torque as shown in Specifications at the beginning of this chapter.
36. Install the upper idler pulley. Tighten the bolt to the specified torque as shown in Specifications at the beginning of this chapter. Make sure the pulley rotates smoothly.
37. Align the timing marks of the camshaft toothed pulleys (fig. 7.21).
38. Install the crankshaft toothed pulley with its flange facing the engine. Be careful not to damage the part of the toothed pulley that serves as the crankshaft position sensor pulse wheel.
39. Turn the crankshaft back to the TDC position. Check the alignment of the TDC marks on the toothed pulley and the oil pump housing, install the holder in place and screw in the bolt (Fig. 7.39).
Fig. 7.39. Align the marks on the crankshaft toothed pulley with the mark on the oil pump housing (A) and install the toothed pulley holder (B) and bolt
40. Install the timing belt, starting from the crankshaft toothed pulley, in the following sequence:
- a) Stage 1: Engage the belt with the crankshaft toothed pulley;
- b) Step 2: Place the belt on the coolant pump toothed pulley;
- c) Step 3: Lift the belt over the left camshaft timing pulley;
- d) Stage 4: Pass the belt under the idler pulley,
- d) Step 5: Lift the belt over the right camshaft timing pulley;
- d) Step 6: Place the belt on the tension pulley.
41. Using a press or vice, slowly compress the belt tensioner plunger (Fig. 7.41). Insert a metal rod, drill, or Allen key into the hole in the plunger and housing. Remove the tensioner from the press or vice.
Fig. 7.41. Lock the tensioner plunger by clamping it in a vice and leaving a rod with a diameter of approximately 1.5 mm; make sure the rubber boot stays in place
42. Install the timing belt tensioner and tighten the bolts to the specified torque shown in the Specifications at the beginning of this chapter. Remove the retaining rod.
43. Using a socket head and extension, slowly turn the crankshaft by the pulley bolt two full turns (720°) clockwise. Again check the position of the timing marks (fig. 7.21).
Caution: If the timing marks are not aligned exactly as shown, repeat the timing belt installation procedure. Do not start the engine until you are absolutely sure that the belt is installed correctly. If the belt is not installed correctly, serious engine damage may occur, requiring costly repairs.
44. Install the belt guide onto the end of the crankshaft with the cupped side facing out.
45. Install the lower (No. 1) timing belt cover and corresponding gasket.
46. Install the pulley (for drive belt) onto the crankshaft, aligning the keyway with the key on the crankshaft. Screw in the bolt and tighten it to the specified torque specified in Specifications at the beginning of this chapter. Hold the crankshaft from turning using the method described in paragraph 17.
47. Install the engine mount thrust support bracket (see paragraph 16).
48. Install the upper (No. 2) timing belt cover and corresponding gasket.
49. Install the engine mount torque rod and tie rods and tighten the bolts securely (see paragraph 16).
50. Reinstall the remaining components in the reverse order of removal.