Timing Belt: Service and Repair

Removal





1. Turn the crankshaft so its white mark (A) lines up with the pointer (B).





2. Check that the No. 1 piston top dead center (TDC) mark (A) on the front camshaft pulley and the pointer (B) on the front upper cover are aligned.
3. Remove the front tires/wheels.





4. Remove the splash shield.
5. Remove the alternator-compressor belt.





6. Loosen the adjusting nut (A), locknut (B) and mounting bolt (C), then remove the power steering (P/S) pump belt (D).
7. Support the engine with a jack and wood block under the oil pan.





8. Remove the side engine mount bracket.





9. Remove the dipstick and tube (A); discard the O-ring (B).
10. Remove the crankshaft pulley.





11. Remove the front upper cover (A) and rear upper cover (B).





12. Remove the lower cover.





13. Remove one of the battery clamp bolts from the battery tray, and grind the end of it as shown.





14. Screw the battery clamp bolt in as shown to hold the timing belt adjuster in its current position. Tighten it by hand, do not use a wrench.





15. Remove the engine mount bracket.





16. Loosen the idler pulley bolt (A) about five or six turns. then remove the timing belt.

Installation

NOTE: The following procedure is for installing a new timing belt. If you are installing a used timing belt, refer to the used timing belt procedure.

New Belt
1. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers.





2. Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump.








3. Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.
4. Remove the battery clamp bolt from the back cover.
5. Remove the auto-tensioner.





6. Align the holes on the rod and housing of the auto-tensioner.
7. Use a hydraulic press to slowly compress the auto-tensioner. Insert a 2.0 mm (0.08 inch) pin through the housing and the rod.

NOTE: The compression pressure should not exceed 9,800 N (1,000 kgf, 2,200 lbs).





8. Install the auto-tensioner.

NOTE: Make sure the pin stays in place.





9. Install the timing belt in a counterclockwise sequence starting with the drive pulley.





10. Tighten the idler pulley bolt.





11. Remove the pin from the auto-tensioner.





12. Install the engine mount bracket.





13. Install the timing belt guide plate as shown.





14. Install the lower cover.





15. Install the front upper cover (A) and rear upper cover (B).
16. Install the crankshaft pulley.
17. Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions on the pulleys.





18. Turn the crankshaft pulley so its white mark (A) lines up with the pointer (B).








19. Check the camshaft pulley marks.
- If the camshaft pulley marks are at TDC, go to step 20.
- If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 2 through 16.





20. Install the dipstick and tube (A) with a new O-ring (B).
21. Install and adjust the power steering (P/S) pump belt.
22. Install the alternator belt.





23. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown.

Used Belt
Follow this procedure when installing a used timing belt.
1. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers.





2. Set the timing belt drive pulley to TDC by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump.








3. Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.
4. If the auto-tensioner has extended and the timing belt cannot be installed, perform the new belt installation procedure.





5. Install the timing belt in a counterclockwise sequence starting with the drive pulley. Take care not to damage the timing belt when installing it.





6. Tighten the idler pulley bolt.





7. Remove the battery clamp bolt from the back cover.





8. Install the engine mount bracket.





9. Install the timing belt guide plate as shown.





10. Install the lower cover.





11. Install the front upper cover (A) and rear upper cover (B).
12. Install the crankshaft pulley.
13. Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions on the pulleys.





14. Turn the crankshaft pulley so its white mark (A) lines up with the pointer (B).








15. Check the camshaft pulley marks.
If the camshaft pulley marks are at TDC, go to step 16. If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 2 through 12.





16. Install the dipstick and tube (A) with a new O-ring (B).
17. Install and adjust the P/S pump belt.
18. Install the alternator belt.





19. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown.