Removal

1. Disconnect the negative battery cable. 2. Remove the two fresh air duct mounting bolts on the radiator. 3. Loosen the fresh air duct clamp at the intake housing. 4. Remove the hose at the resonance chamber. 5. Remove the frech air duct. 6. Remove the five cooling fan shroud bolts. 7. Remove the four thermo-modulated fan nuts. 8. Remove the four thermo-modulated fan cooling fan shroud at the same times. 9. Loosen the two generator mounting bolts(A and B). 10. Loosen the generator drive belt from the generator by loosening the adjusting bolt(C). 11. Remove the generator drive belt. 12. Remove the fan pulley. 13. Remove the four splash guard mounting bolts and splash guard. 14. Loosen the A/C idler puller nut(A). 15. Remove the A/C drive belt by loosening the adjusting bolt. 16. Loosen the power steering pump lock bolt and mounting bolt. 17. Remove the power steering belt. 18. Remove five bolts and the upper timing belt cover. Refer to Timing Belt. 19. Remove two bolts and the lower timing cover. Refer to Timing Belt. 20. Loosen the tensioner lock bolt and pivot the tensionder pulley outward to remove the tension from the timing belt, then re-tighten the tensioner lock bolt. Tightening Torque : 27-38ft·lbs(37-52N·m) 21. Mark the timing belt rotation for proper reinstallation if it reused. 22. Remove the timing belt. Be careful not to allow oil grease on the belt. Removal(Timing Belt Pulley) 1. Refer to Timing Belt Removal. 2. Remove the timing belt pulley lock bolt. 3. Remove the timing belt pulley. Removal(Camshaft Pulleys) 1. Refer to Timing Belt Removal. 2. Remove the camshaft pulley lock bolts. 3. Remove the camshaft pulleys. Removal 1. Remove in the sequence shown in the figure below. Refer to Toming Belt. 2. Loosen the tensioner lock bolt, and pivot the tensioner oulley outward, removing the tension from the timing belt and tighten the tensioner lock bolt. Tightening torque : 27-38ft·lb (37-52N·m) 3. Mark the timing belt rotation for proper reinstallation if it is resued. 4. Remove the timing belt. Be careful not to allow oil or grease on the belt. Camshaft Pulleys 1. Hold the camshafts with a suitable wrench. 2. Remove the camshaft pulley lock bolts and the camshaft pulleys. Installation 1. Align the timing belt pulley and the pump body alignment marks. 2. Align the mating marks on the camshaft pulleys with the alignment marks on the seal plate. • For intake side camshaft pullet, align “I” mark • For exhaust side camshaft pulley, align “E” mark. 3. Install the timing belt so there is no looseness at the tension side, and at the two camshaft pulleys. • If the timing belt is being, it must be reinstalled to rotate in the original direction. • Check that there is no oil, grease, or dirt on the timing belt. 4. Loosen the tensioner lock bolt. 5. Turn the crankshaft two camplete revolutions in the direction of rotation. 6. Check that the mating marks are correctly aligned. If not aligned correctly, remove the timing belt and tensioner, and return to step 1. 7. Turn the crankshaft to align the “S”mark of the exhaust camshaft pulley with the seal plate mating mark. 8. Tighten the timing belt tensioner lock bolt. Tightening torque : 27-38ft·lb(32-52N·m, 3.8-5.3kg·m) 9. Check the timing belt deflection. If the deflection is not correct, loosen the tensioner lock bolt and repeat steps 5-7 above. Replace the tensioner spring if necessary. Belt deflection : 0.30-0.33 in.(7.5-8.5mm)／22lb(98N, 10kg) 10. Install the lower timing belt cover and two bolts. Refer to Timing Belt. Tightening torque : 61-87in·lb(7-10N·m) 11. Install the upper timing belt cover and five bolts. Refer to Timing Belt. Tightening torque : 61-87in·lb(7-10N·m) 12. Install the power steering drive belt and set belt deflection. Power Steering Belt deflection : New : 0.31-0.39in.(8-10mm) Used : 0.35-0.43in.(9-11mm) 13. Tighten the lock bolt(A) and mounting bolt(B). Tightening torque : 27-34in·lb(37-46N·m) 14. Install the fan pulley. 15. Install the generator drive belt and adjust belt deflection by tightening adjusting bolt(C). Generator Belt deflection : New : 0.24-0.31in.(6-8mm) Used : 0.27-0.35in.(7-9mm) 16. Tighten generator mounting bolts(A and B). Tightening torque : A : 16 ft·lb(22N·m) B : 32ft·lb(45N·m) 17. Install A/C drive belt and set belt deflection by tightening adjusting bolt(B). A/C Belt deflection : New : 0.27-0.35in.(7-9mm) Used : 0.31-0.39in.(8-10mm) 18. Tighten the adjusting bolt(B) and idler pulley bolt(A). Tightening torque : 23-25 ft·lb(31-34N·m) 19. Install the splash guard tighten the four mounting bolts. 20. Install the fan and shroud. 21. Install the four fan bolts and tighten. Tightening torque : 24ft·lb(32.6N·m) 22. Install the five fan shroud mounting bolts. Tightening torque : 69-95 in·lb(7.8-11N·m) 23. Install the fresh air duct. 24. Install the hose at the resonance chamber. 25. Install and tighten the clamp at the air intake housing. 26. Install the two fresh air duct mounting bolts and tighten. Tightening torque : 69-95 in·lb(7.8-11N·m) 27. Reconnect the negative battery cable. Installation(Timing Belt Pulley) 1. Install the timing belt pulley with the mating marks aligned. 2. Position the guide plate as shown. 3. Install the lock bolt and tighten. Tightening torque : 120 ft·lb(162N·m) 4. Install timing belt as described in this section. Installation 1. Install the camshaft pulleys as shown on the illustration. making sure that the dowel pins and "I"(intake) and "E"(exhaust) marks are pointing up. 2. Install the camshaft pulley lock bolts and tighten. Tighten torque : 35-48 ft·lb(47-65 N·m) 3. Refer to Timing Belt Installation. Installation(Camshaft Pulleys) 1. Install the camshaft pulleys on the camshaft with the dowel pins fit into the hole at the I mark(intake side) and E mark.(exhaust). 2. Tighten the camshaft pulley lock bolts. Tightening torque : 35-48ft·lb (47-65N·m) 3. Align the matings on the camshaft pully with the alignment marks on the seal plate. • For intake side camshaft pulley, align "I" mark. • For exhaust side camshaft pulley, align "E" mark. Timing Belt Pulley 1. Reverse the direction of the SST(ring gear brake). 2. Install the crankshaft woodruff key. 3. Install the timing belt pulley onto the crankshaft. Tightening torque : 116-123 ft·lb(157-167N·m) 4. Release the ring gear brake. 5. Align the timing belt pulley and the pump body alignment marks. Timing Belt Idler Pulley Install the timing belt idler pulley. Tightening torque : 27-38 ft·lb(37-52N·m) Timing Belt Tensiner 1. Install the timing belt tensioner pulley and tensioner spring. 2. Temporarily secure the tensioner pulley with the spring fully extended. Timing Belt 1. Install the timing belt so that there is no looseness at the tension side and between the two camshaft puellys. • If the timing belt is being reused, it must be reinstalled to rotate in the original direction. • Check that there is no oil, grease or dirt on the timing belt. 2. Loosen the tensioner lock bolt. 3. Turn the crankshaft twice in the dirction of rotation. 4. Check that the mating marks are correctly aligned. If not aligned, remove the timing belt, retract the tensioner, and repeat the timing belt installation procedure. 5. Turn the crankshaft to align the S mark of the exhaust camshaft pulley with seal plate mating mark. 6. Tighten the timing belt belt tensioner lock bolt. Tightening torque : 27-38 ft·lb(37-52N·m) 7. Check the timing belt deflection. If the deflection is not correct, loosen the tensioner lock b olt and repeat steps 3-5 above. Replace the tensioner spring necessary. Belt deflection : 0.30-0.33 in.(7.5-8.5mm)/22lb(98N, 10kg) Timing Belt Guide Plate 1. Position the timing belt guide plate on the timing belt pulley. Timing Belt Cover Install the lower timing belt cover, upper timing belt cover, and new gasket. Tightening torque : 72-84 in·lb(7-10N·m) Inspection 1. Replace the timing belt if there is any oil or grease on it. 2. Check the timing belt for damage, wear, peeling, cracks, or hardening. Replace if necessary. • Never forcefully twist, turn inside out, or bend the timing belt. • Be careful not to allow oil grease on the belt. Tensioner and Idler Pulley 1. Check the timing belt tensioner and idler pulleys for smooth rotation and abnormal noise. Replace if necessary. Do not clean the tensioner pulley with cleaning fluids. If necessary, use a soft rag to wipe it clean, and avoid scratching it. Tensioner Spring 1. Check the free length of the tensioner spring. Replace if necessary. Free length : 2.189 in.(55.6mm) max. Timing Belt Pulley and Camshaft Pulleys 1. Inspect the pulley teeth for wear, deformation, or other damage. Replace if necessary Do not clean the pulley with cleaning fluids. If necessary use a rag to wipe it clean. Timing Belt Cover(Lower and Upper) Inspect the timing belt covers for damage or cracks. Replace if necessary.

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