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First, this is an interference engine, so I understand your concern. Do not engage the starter if you question it. Simply turn the crankshaft slowly with a wrench to confirm there is nothing interfering between the pistons and cylinder head.
I'm not sure what you mean by the pistons are closed. Please explain. Also, I looked at both 02 and 07 timing marks in the manual and they are the same. Explain exactly what is happening.
Here are the directions specific to a 1992. Take a look through these directions to see if you missed anything. The attached pictures correlate with the directions.
TIMING BELT REMOVAL AND INSTALLATION
TIMING BELT REMOVAL
Timing belt removal
1. Remove the tension spring.
2. Loosen bolt "B", and draw the tension pulley fully to the water pump side and temporarily tighten bolt "B".
3. Remove the timing belt.
TIMING BELT INSPECTION
Caution in handling
1. Do not bend in less than 20 mm in radius.
2. Avoid twisting or kinking the belt and keep it free from water, oil, dust and other foreign matter.
1. The belt must be replaced if cracks or lacerations are found in the side and rear faces.
2. Replacement is necessary when abnormal wear is found in the side face.
3. Replacement is necessary when belt fabric is found to be cracked or disintegrated.
4. Replacement is also necessary when cogs are found to have abnormal wear.
5. Take measurements at 3 - 5 points around the circumference of the belt The belt must be replaced even if a single measurement is beyond the limit.
Limit of rubber hardness - 90 (HS)
TIMING PULLEY AND TENSION SPRING INSPECTION
Oil pump pulley
If uneven wear, cracks or wear exceeding the limit are found in the pulley, replace it with a new one.
Timing Pulley Outside Diameter
Tension pulley outside diameter
1. Check the roller for excessive wear and damage.
2. Check to see that the roller rotates smoothly.
3. Check to see that there is no play in the pulley shaft/fixing plate sealing area.
Tension Spring Tension
If the set length or set force is out of the specified range, replace the tension spring with a new one.
TIMING BELT INSTALLATION
1. Timing belt
Install the timing belt in the sequence indicated.
1. Align the matchmarks of the crankshaft timing pulley with that of the front oil seal retainer.
Fig. 20 Aligning camshaft timing pulley & front plate
2. Align the matchmarks of the camshaft timing pulley with that of the front plate.
Note: At this point the No.4 cylinder comes to its compression, top dead center.
3. Lay the timing belt over the crank pulley, oil pump pulley, cam pulley, and tension pulley in the indicated order, avoiding any loosening between them.
4. Loosen bolt "B" to allow the tension spring to tighten the belt.
5. Temporarily tighten bolt "B".
6. Temporarily attach the crank pulley.
7. Turn the crankshaft two revolutions in the opposite direction of normal rotation to align the crankshaft matchmarks with the crankshaft timing pulley matchmarks.
8. Loosen bolt "B" and tighten the belt with the tension pulley.
9. Tighten bolt "B" to the specified torque.
Torque: 1.9 kg-m (13.7 ft. Lbs)
2. Timing belt cover (upper and lower)
Attach the timing belt cover and tighten to the specified torque.
Torque: 0.6 kg-m (4.4 ft. Lbs)
3. Crankshaft pulley
Apply Pulley to the crankshaft and tighten crankshaft pulley bolt to the specified torque.
Torque: 12.0 kg-m (86.7 ft. Lbs)
Let me know if this helps or if you have other questions.
Images (Click to enlarge)
Friday, June 7th, 2019 AT 7:37 PM