Timing Belt: Service and Repair

Part 1 Of 4:

Part 2 Of 4:

Part 3 Of 4:

Part 4 Of 4:

REMOVAL
1. REMOVE OIL PAN PROTECTOR
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. REMOVE BATTERY CLAMP COVER
5. REMOVE V-BANK COVER
a. Remove the fuel return hose from the V-bank cover.
b. Remove the 2 bolt, 2 cap nuts and V-bank cover.
6. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY





7. REMOVE DRIVE BELT FAN, FLUID COUPLING AND FAN PULLEY
a. Loosen the 4 nuts holding the fluid coupling to the fan bracket.
b. Remove the generator drive belt.
c. Remove the 4 nuts, the fan, the fluid coupling assembly and the fan pulley.
8. REMOVE RADIATOR ASSEMBLY
9. REMOVE DRIVE BELT IDLER PULLEY
Remove the pulley bolt, the cover plate and the idler pulley.





10. REMOVE RH NO.3 TIMING BELT COVER
Remove the 3 bolts, the nut and the RH No.3 timing belt cover.





11. REMOVE LH NO.3 TIMING BELT COVER
a. Disconnect the engine wire from the 2 wire clamps.
b. Remove the 4 bolts and the nut.
c. Disconnect the camshaft position sensor wire from the wire clamp on the LH No.3 timing belt cover.
d. Disconnect the sensor connector from the connector bracket.
e. Disconnect the sensor connector.
f. Remove the wire grommet from the LH No.3 timing belt cover.
g. Remove the LH No.3 timing belt cover.
h. Remove the oil cooler pipe and the 2 bolts.





12. REMOVE NO.2 TIMING BELT COVER
Remove the 2 bolts and the No.2 timing belt cover.
13. DISCONNECT A/C COMPRESSOR FROM ENGINE





14. REMOVE FAN BRACKET
Remove the 2 bolts, the 2 nuts and the fan bracket.





15. IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT
Check that there are 3 installation marks on the timing belt as turning the crankshaft pulley as shown in the illustration.

HINT: If the installation marks are disappeared, place a new installation mark on the timing belt before removing each part.





16. LOOSEN CRANKSHAFT PULLEY BOLT
Using SST, loosen the pulley bolt.
SST 09213-70011 (90105-70020), 09330-00021
17. SET NO.1 CYLINDER TO TDC/COMPRESSION





a. Turn the crankshaft pulley and align its groove with the timing mark "0" of the No.1 timing belt cover.





b. Check that the timing marks of the camshaft timing pulleys and that of the timing belt rear plates aligned. If not, turn the crankshaft 1 revolution (360°).
c. Remove the crankshaft pulley bolt.

NOTICE: Do not turn the crankshaft pulley.

18. REMOVE TIMING BELT TENSIONER

HINT:





^ When re-using timing belt: If the installation marks are disappeared, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys before the removal.





^ When replacing timing belt tensioner only: To avoid meshing of the timing pulley and the timing belt, secure one of them with string, and then place matchmarks on the timing belt and the RH camshaft timing pulley.





Alternately loosen the 2 bolts, and remove the belt tensioner and the dust boot.





19. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS
a. Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise.
SST 09960-10010 (09962-01000, 09963-01000)
b. Disconnect the timing belt from the camshaft timing pulleys.





20. REMOVE CAMSHAFT TIMING PULLEYS
Using SST, remove the bolt and the timing pulley. Remove the 2 timing pulleys.
SST 09960-10010 (09962-01000, 09963-01000)
21. REMOVE GENERATOR
22. REMOVE DRIVE BELT TENSIONER
Remove the bolt, 2 nuts and the belt tensioner.





23. REMOVE CRANKSHAFT PULLEY
Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09950-05011, 09953-05020, 09954-05021)

NOTICE: Do not turn the crankshaft pulley.

24. REMOVE NO.1 TIMING BELT COVER
Remove the 4 bolts and the timing belt cover.





25. REMOVE TIMING BELT GUIDE
26. REMOVE TIMING BELT COVER SPACER





27. REMOVE TIMING BELT

HINT: If re-using the belt and the installation mark is disappeared from it, place a new installation mark on the timing belt to the match the dot mark on the crankshaft timing pulley.





28. REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
a. Using a 10 mm hexagon wrench, remove the bolt, the No.1 idler pulley and the plate washer.
b. Remove the bolt and the No.2 idler pulley.





29. REMOVE CRANKSHAFT TIMING PULLEY
Using SST, remove the timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05011, 09950-05021)

NOTICE: Do not turn the timing pulley.

INSPECTION





1. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.

If there are any defects as shown in the illustrations, check these points:
a. 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 the water pump.
d. Even if there is wear or damage on 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 timing cover for damage and for foreign materials on the pulley teeth.
If necessary, replace the timing belt.





2. INSPECT IDLER PULLEYS
a. Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
b. Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TIMING BELT TENSIONER





a. Visually check the seal portion of the tensioner for oil leakage.

HINT: if there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right.

If leakage is found, replace the tensioner.





b. Hold the tensioner with both hands, and push the push rod strongly to check that it doesn't move. If the push rod moves, replace the tensioner.

NOTICE: Never hold the tensioner push rod facing downward.





c. Measure the protrusion of the push rod from the housing end.
Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 inch)
If the protrusion is not as specified, replace the tensioner.
4. INSPECT WATER PUMP

INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the timing pulley set key with the key groove of the pulley.





b. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.
SST 09223-06011





2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
a. Apply adhesive 2 or 3 threads from the end of the pivot bolt.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a 10 mm hexagon wrench, install the plate washer and the No.1 idler pulley with the pivot bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the No.2 idler pulley with the bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
d. Check that the No.1 and No.2 idler pulley moves smoothly.





3. TEMPORARILY INSTALL TIMING BELT

NOTICE: The engine should be cold.

a. Remove any oil or water on and clean the crankshaft pulley, the oil pump pulley, the water pump pulley, the No.1 idler pulley and the No.2 idler pulley.

NOTICE: Only wipe the pulleys; do not use any cleansing agent.

b. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
c. Install the timing belt on the crankshaft timing pulley, the No.1 idler pulley and the No.2 idler pulley.
4. INSTALL TIMING BELT COVER SPACER
a. Install the gasket to the cover spacer.
b. Install the cover spacer.





5. INSTALL TIMING BELT GUIDE
Install the belt guide, facing the cup side outward.
6. INSTALL NO.1 TIMING BELT COVER
Install the timing belt cover with the 4 bolts.
7. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the crankshaft pulley.





b. Using SST and a hammer, tap in the crankshaft pulley.
SST 09223-46011
8. INSTALL DRIVE BELT TENSIONER
Install the belt tensioner with the bolt and the 2 nuts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)

HINT: Use a bolt of 106 mm (4.18 inch) in length.

9. INSTALL GENERATOR





10. CHECK CRANKSHAFT PULLEY POSITION
Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No.1 timing belt cover.
11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS
a. Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley.





b. Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
12. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY





a. Remove any oil or water on the LH camshaft timing pulley, and clean it up.

NOTICE: Only wipe the pulleys; do not use any cleansing agent.





b. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley.
c. Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and the LH camshaft timing pulley.





13. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY
a. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and clean them up.

NOTICE: Only wipe the pulleys; do not use any cleansing agent.

b. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley.





14. SET TIMING BELT TENSIONER
a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbs.) of pressure.
b. Align the holes of the push rod and the housing, pass a 1.27 mm (0.050 inch) hexagon wrench through the holes to keep the setting position of the push rod.
c. Release the press.
d. Install the dust boot to the belt tensioner.





15. INSTALL TIMING BELT TENSIONER
a. Temporarily install the belt tensioner with the 2 bolts.
b. Alternately tighten the 2 bolts.
Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.)
c. Using pliers, remove the 1.27 mm (0.050 inch) hexagon wrench from the belt tensioner.
16. CHECK VALVE TIMING





a. Temporarily install the crankshaft pulley bolt.
b. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

NOTICE: Always turn the crankshaft pulley clockwise.





c. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it.





17. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST, install the pulley bolt.
SST 09213-70011 (90105-70020), 09330-00021
Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.)





18. INSTALL FAN BRACKET
Install the fan bracket with the 2 bolts and the 2 nuts.
Torque: 12 mm head 16 Nm (160 kgf-cm, 12 ft. lbs.)
14 mm head 32 Nm (330 kgf-cm, 24 ft. lbs.)

HINT: Bolt Length:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)

19. INSTALL A/C COMPRESSOR





20. INSTALL NO.2 TIMING BELT COVER
Install the No.2 timing belt cover with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





21. INSTALL RH NO.3 TIMING BELT COVER
a. Fit the RH No.3 timing belt cover, matching it with the fan bracket.
b. Install the RH No.3 timing belt cover with the 3 bolts and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)





22. INSTALL LH NO.3 TIMING BELT COVER
a. Install the oil cooler pipe and the bolt.
b. Run the camshaft position sensor wire through the LH No.3 timing belt cover hole.
c. Fit the LH No.3 timing belt cover, matching it with the fan bracket.
d. Install the LH No.3 timing belt cover with the 4 bolts and the nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
e. Install the wire grommet to the LH No.3 timing belt cover.
f. Install the sensor connector to the connector bracket.
g. Connect the sensor connector.
h. Install the sensor wire to the wire clamp on the LH No.3 timing belt cover.
i. Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover.
23. INSTALL DRIVE BELT IDLER PULLEY
Install the idler pulley and the cover plate with the bolt.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
24. INSTALL RADIATOR ASSEMBLY





25. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT
a. Temporarily install the fan pulley, the fan, the fluid coupling assembly with the 4 nuts.
b. Install the generator drive belt.
c. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
Torque: 21 Nm (215 kgf-cm, 16 ft. lbs.)
26. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
27. INSTALL V-BANK COVER
28. FILL WITH ENGINE COOLANT
29. START ENGINE AND CHECK FOR LEAKS
30. RECHECK ENGINE COOLANT LEVEL
31. INSTALL BATTERY CLAMP COVER
32. INSTALL ENGINE UNDER COVER
33. INSTALL OIL PAN PROTECTOR