For 1990-2009 cars

#### Special Tools

• | EN-48245 Camshaft Locking Tool

• | EN-48946 Crankshaft Locking Tool

For equivalent regional tools, refer to Special Tools.

### Removal Procedure

1. Remove engine cover. Refer to Engine Cover Replacement.
2. Remove air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
3. Raise vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
4. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement.
5. Remove the generator and air conditioning compressor and power steering pump belt. Refer to Generator and Air Conditioning Compressor and Power Steering Pump Belt Replacement.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
7. Remove the belt idler pulley. Refer to Belt Idler Pulley Replacement.
8. Remove the charge air cooler inlet air tube bolt (4).
9. Remove the 2 hose clamps (3).
10. Remove the 3 air charge air cooler inlet air tube bolts (1).
11. Remove the charge air cooler inlet air tube (2).
12. Rotate the crankshaft to the markings at the crankshaft sprocket and oil pump cover.
13. Remove the lower crankcase closure bolt (5).

Install EN-48245 locking tool (4) into the lower crankcase hole (3). Turn the crankshaft until the tool engages into the crankshaft.

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14. Install mounting engine/transmission. Refer to Engine/Transmission Mounting.
15. Remove the generator and air conditioning compressor and power steering pump belt. Refer to Generator and Air Conditioning Compressor and Power Steering Pump Belt Replacement.
16. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Removal.
17. Remove the belt idler pulley. Refer to Drive Belt Idler Pulley Removal.
18. Remove the crankshaft idler pulley. Refer to Crankshaft Pulley Replacement.
19. Remove timing belt lower front cover. Refer to Timing Belt Lower Front Cover Removal.
20. Lower the vehicle full height.
21. Remove the engine right mount. Refer to Engine Mount Replacement - Right Side.
22. Remove the steering pump bolts (1, 2).

Note: Do not disconnect the power steering hoses.

23. Remove the steering pump (2) out of the work area.
24. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal.
25. Remove the vacuum pump. Refer to Vacuum Pump Removal.

Note:

• | Examine that the bore (1) inside the camshaft (2) is on top.

• | Examine the correct positions of the camshaft and the crankshaft.

26. Rotate the camshaft (1) to the position as shown in the graphic.
27. If the markings from crankshaft and camshaft not align remove the EN-48245 locking tool turn the crankshaft 360° and install EN-48245 locking tool . Refer to step 11.
28. Install the EN-48946 locking tool (1) to fix the camshaft and install the 4 bolts (2) and tighten to 12 N·m (107 ft in).
29. Loosen the timing belt tensioner bolt (2).
30. Turn the timing belt tensioner with an hex-key (1) clockwise until the timing belt is solved.
31. Remove the timing belt (1).

### Installation Procedure

1. Rotate the fuel pump drive sprocket that the marks (1) and (2) align.

Note: Examine the correct traveling direction of the timing belt.

2. Install the Timing Belt (1) in the following order:

Note: Examine that the timing belt is tensioned during the installation.

2.1. | Crankshaft sprocket (7)

2.2. | Water pump pulley (6)

2.3. | Fuel pump drive pulley (4)

2.4. | Timing belt idler pulley (3)

2.5. | Camshaft drive sprocket (2)

2.6. | Timing belt tensioner (5)

3. Turn the hex-key (1) tab in a counterclockwise direction to tension the belt. Turn until the point aligns with the notch (2).

Caution: Refer to Fastener Caution in the Preface section.

4. Aligning with (2) notch, tighten the timing belt tensioner bolt (3) to 25 N·m (19 lb ft).
5. Remove the EN-48946 locking tool (1) and remove the bolts (2).
6. Raise vehicle by its full height.
7. Remove EN-48245 locking tool (4) from the lower crankcase hole (3). Install the lower crankcase closure bolt (5) and tighten to 30 N·m (23 lb ft).
8. Turn the crankshaft in a clockwise direction 2 cycles and check the positions from the crankshaft.

Note: If the timing marks are not aligned, repeat the forward procedure and recheck the marks. Alignment of marks is important for engine performance and emissions.

9. Lower the vehicle full height.
10. Check the camshaft position.

Note:

• | Examine that the bore (1) in the camshaft (2) is on top.

• | Examine the correct positions of the camshaft and the crankshaft.

11. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation.
12. Install the vacuum pump. Refer to Vacuum Pump Installation.
13. Install the engine right mount. Refer to Engine Mount Replacement - Right Side.
14. Install the steering pump (2).
15. Install the steering pump bolts (1, 2) and tighten to 22 N·m (16 lb ft).
16. Raise the vehicle by its full height.
17. Install the timing belt lower front cover. Refer to Timing Belt Lower Front Cover Installation.
18. Install the crankshaft idler pulley. Refer to Crankshaft Pulley Installation.
19. Install the drive belt tensioner. Refer to Drive Belt Tensioner Installation.
20. Install the belt idler pulley. Refer to Belt Idler Pulley Installation.
21. Install the generator and air conditioning compressor and power steering pump belt. Refer to Generator and Air Conditioning Compressor and Power Steering Pump Belt Replacement.
22. Remove mounting engine/transmission. Refer to Engine/Transmission Mounting.
23. Install the charge air cooler inlet air tube (2).
24. Install the 3 charge air cooler inlet air tube bolts (1) and tighten to .
25. Install the 2 hose clamps (3).
26. Install the charge air cooler inlet air tube bolt (4) and tighten to 10 N·m (89 lb in).
27. Install the belt idler pulley. Refer to Belt Idler Pulley Replacement.
28. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
29. Install the generator and air conditioning compressor and power steering pump belt. Refer to Generator and Air Conditioning Compressor and Power Steering Pump Belt Replacement.
30. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement.
31. Lower the vehicle full height.
32. Install air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
33. Install engine cover. Refer to Engine Cover Replacement.