Installation

3MZ-FE ENGINE MECHANICAL: TIMING BELT:

INSTALLATION

1. INSPECT TIMING BELT
NOTICE:
- Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects as shown in the illustration. Also, check the points below.






(a) If there is premature parting:
- Check for proper installation.
- Check the timing cover gasket for damage and proper installation.

(b) If the belt teeth are cracked or damaged, check if either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
(d) If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:
- Check the timing cover for damage.
- Check that the gasket has been installed correctly.
- Check for foreign object on the pulley teeth.
If there is any trouble in the belt condition, replace the timing belt.
2. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, and keep them clean.
NOTICE:
- If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
- Wipe only the pulleys; do not use any cleaning agent.

(b) Inspect the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for oil leakage.
(c) Inspect the water pump.
(1) Turn the pulley, and check that the water pump bearing moves smoothly and does not make any noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.






(e) Turn the crankshaft counterclockwise by approximately 60°.
NOTE: To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.





(f) Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No.3 timing belt cover.
SST: 09960-10010
09962-01000
09963-01000
NOTE: Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.





(g) Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.






(h) Face the front mark on the timing belt forward.
(i) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
(j) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.






(k) Install the timing belt in the following order.





NOTE: Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.

3. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
(a) Set the timing belt tensioner upright on the press.






(b) Slowly press in the push rod.
NOTE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.

(c) Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 Nm (280 kgf-cm, 20 ft-lbf)
NOTE: Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause improper operation.

(f) Remove the 1.5 mm hexagon wrench from the tensioner.






(g) Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body.
NOTE: Always turn the crankshaft clockwise.





(h) Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No.3 timing belt cover as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
(i) Remove the crankshaft pulley bolt.
4. INSTALL TIMING BELT GUIDE NO.2






(a) Install the timing belt guide with the cup side facing toward the engine front.
5. INSTALL ENGINE MOUNTING BRACKET RH






(a) Install the engine mounting bracket RH with the 2 bolts and 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
6. INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If a trace of water is found in the visual check, replace the timing belt cover.






(b) Install the timing belt cover with the 5 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
(c) Connect the 2 clamps.
7. INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If a trace of water is found in the visual check, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
(c) Install the engine wire protector cover to the timing belt No.3 cover.
8. INSTALL CRANKSHAFT PULLEY






(a) Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
(b) Using SST, install the pulley bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 220 Nm (2,250 kgf-cm, 162 ft-lbf)
9. INSTALL ENGINE MOUNTING STAY NO.2 RH






(a) Install the engine mounting stay No.2 and the engine mounting bracket No.2 with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
10. INSTALL ENGINE MOVING CONTROL ROD






(a) Temporarily tighten bolts B and C.
(b) First tighten bolt A, bolt B and bolt C.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
(c) Tighten bolt D.
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
11. INSTALL AIR CLEANER BRACKET Installation

12. INSTALL RESERVOIR BRACKET Installation

13. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Installation

14. INSTALL AIR CLEANER CASE W/ RESONATOR Removal

15. INSTALL AIR CLEANER CAP W/ INLET Installation

16. INSTALL COOL AIR INTAKE DUCT SEAL Installation

17. INSTALL BATTERY CARRIER SUB-ASSEMBLY Installation

18. INSTALL BATTERY Installation

19. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER Installation

20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

21. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
22. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

23. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

24. INSTALL FRONT FENDER APRON SEAL RH






(a) Install the 2 bolts, clip and fender apron seal RH.
25. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH






(a) Install the fender splash shield with the screw.
26. INSTALL ENGINE UNDER COVER NO.1 Installation

27. INSTALL FRONT WHEEL RH
28. INSPECT IGNITION TIMING Testing and Inspection

29. PERFORM INITIALIZATION
(a) Some system need initialization when reconnecting the cable from the battery terminal. Repair Instruction - Initialization

30. INSTALL ENGINE ROOM COVER SIDE Installation

31. INSTALL ENGINE ROOM SIDE LH COVER NO.2 Installation