Timing Belt: Service and Repair

TIMING BELT

COMPONENTS:

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

2. REMOVE ENGINE REAR UNDER COVER
a. Remove the 8 bolts and engine under cover.
3. REMOVE NO. 1 ENGINE UNDER COVER
a. Remove the 5 bolts and engine under cover.
4. DRAIN ENGINE COOLANT
5. REMOVE V-BANK COVER
6. REMOVE AIR CLEANER HOSE ASSEMBLY
7. REMOVE AIR CLEANER ASSEMBLY
a. Disconnect the MAF meter connector.
b. Remove the air cleaner cap and air cleaner element.
c. Remove the 3 bolts and air cleaner case assembly
8. DISCONNECT NO. 1 RADIATOR HOSE
9. DISCONNECT NO. 2 RADIATOR HOSE
10. DISCONNECT NO. 1 OIL COOLER INLET TUBE
11. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE
12. REMOVE DRIVE BELT
13. REMOVE RADIATOR ASSEMBLY
14. DISCONNECT VANE PUMP ASSEMBLY
15. REMOVE GENERATOR ASSEMBLY
16. DISCONNECT COMPRESSOR ASSEMBLY

17. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY RH
a. Remove the cap nut, 3 bolts, timing belt cover and gasket.

18. REMOVE OIL COOLER PIPE
a. Remove the cap nut and bolt.
b. Disconnect the oil cooler pipe from the timing belt cover.
c. Disconnect the 3 water by-pass hoses from the oil cooler pipe.

19. REMOVE NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH
a. Disconnect the engine wire from the 2 wire clamps.
b. Disconnect the camshaft position sensor connector.
c. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
d. Remove the wire grommet from the timing belt cover.
e. Remove the 4 bolts.
f. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
g. Disconnect the wire clamp for the sensor from the timing belt cover.
h. Remove the connector holder from the sensor connector.
i. Remove the timing belt cover.

20. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Remove the pulley bolt, cover plate and idler pulley.

21. REMOVE NO. 2 TIMING BELT COVER SUB-ASSEMBLY
a. Remove the 2 bolts and timing belt cover.

22. REMOVE DRIVE BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and belt tensioner.

23. REMOVE IDLER PULLEY ASSEMBLY
a. Remove the 2 bolts, 2 nuts and idler pulley
24. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

a. Using SST, remove the damper bolt.
SST 09213-70011 (09213-70020), 09330-00021

b. Using SST, remove the damper.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)

25. REMOVE NO. 1 TIMING BELT COVER
a. Remove the 4 bolts and cover.
26. REMOVE CRANKSHAFT POSITION SENSOR PLATE
27. REMOVE TIMING BELT
a. Set the No. 1 cylinder to approximately 45° BTDC/compression.

1 Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body

2 Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 revolution (360°).

3 Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 45°.

NOTICE: If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

b. If planning to reuse the belt, check the installation marks on the timing belt.
1 Check that there are 3 installation marks on the belt by turning the crankshaft as shown in the illustration. If the installation marks have disappeared, place new installation marks on the belt before removing each part.

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

d. Using SST, loosen the tension between the camshaft timing pulley (RH) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH) counterclockwise.
SST 09960-10010 (09962-01000, 09963-00350)
e. Disconnect the belt from the No. 1 timing belt idler, and remove the belt.

INSTALLATION
1. INSTALL TIMING BELT
a. Check the No. 1 and No. 2 belt idlers.
1 Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler.
2 Check that the idler turns smoothly. If necessary, replace the idler.

b. Check the water pump.
1 Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump and belt.
2 Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.
c. Remove any oil or water on the crankshaft, oil pump pulley, water pump pulley, No. 1 and No. 2 belt idlers. Keep them clean.

NOTICE: Only wipe the pulleys. Do not use any cleansing agents on the pulleys.

d. Set the No. 1 cylinder to TDC/compression.
1 Turn the hexagon head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

HINT: Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.

Camshaft timing pulley LH: 1/2 of a tooth
Camshaft timing pulley RH: 1 tooth

2 Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body

3 Remove any oil or water on each pulley Keep them clean.

NOTICE: Only wipe the pulleys. Do not use cleaning agents on the pulleys.

4 Face the front mark (arrow) on the belt forward
5 Connect the belt to the crankshaft timing pulley. Align the installation mark on the belt with the timing mark of the crankshaft timing pulley.
6 Connect the belt to the No. 2 belt idler.
7 Connect the belt to the camshaft timing pulley LH. Align the installation mark on the belt with the timing mark of the camshaft timing pulley.
8 Connect the belt to the water pump pulley.
9 Connect the belt to the camshaft timing pulley RH. Align the installation mark on the belt with the timing mark of the camshaft timing pulley
10 Connect the timing belt to the No. 1 belt idler.

e. Set the belt tensioner.
1 Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbs.) of pressure.
2 Align the holes of the push rod and housing.
Pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
3 Release the press.
4 Install the dust boot to the belt tensioner.

f. Install the belt tensioner.
1 Temporarily install the belt tensioner with the 2 bolts.
2 Alternately tighten the 2 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
3 Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.

g. Check the valve timing.
1 Using the crankshaft damper bolt, slowly turn the crankshaft timing pulley 2 revolutions from TDC to TDC.

NOTICE: Always turn the crankshaft pulley clockwise.

2 Check that each pulley aligns with the timing marks as shown in the illustration. If the pulley and timing marks do not align, remove the belt and reinstall it.
3 Remove the crankshaft damper bolt.

2. INSTALL CRANKSHAFT POSITION SENSOR PLATE
a. Install the sensor plate as shown in the illustration.

NOTICE: Be careful of the installation direction.

3. INSTALL NO. 1 TIMING BELT COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
4. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

a. Align the damper set key with the key groove of the crankshaft damper.
b. Using SST and a hammer, tap in the damper.
SST 09223-46011

c. Using SST, install the damper bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)

5. INSTALL FAN BRACKET SUB-ASSEMBLY
a. Install the fan bracket with the 2 bolts and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.) for 12 mm head
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head
Bolt length:
106 mm (4.17 inch) for 12 mm head bolt A
114 mm (4.49 inch) for 14 mm head bolt B

6. INSTALL DRIVE BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

HINT: Use a bolt that is 106 mm (4.17 inch) in length.

7. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY
a. Set the belt cover by matching the claws and pin with each part.
b. Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

HINT: Use bolts that are 106 mm (4.17 inch) in length.

8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (298 kgf-cm, 29 inch lbs.)

9. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH
a. Install the gasket to the belt cover.
b. Pass the camshaft position sensor wire through the cover hole.
c. Install the cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
d. Install the wire grommet to the belt cover.
e. Install the sensor connector to the sensor holder.
f. Connect the sensor connector.
g. Install the sensor wire to the wire clamp on the cover.
h. Install the engine wire to the 2 wire clamps on the cover.

10. INSTALL OIL COOLER PIPE
a. Connect the 3 water by-pass hoses as shown in the illustration.
b. Install the oil cooler pipe to the cover with the cap nut and the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

11. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH
a. Install the gasket to the belt cover.
b. Install the cover with the cap nut and 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
12. CONNECT COMPRESSOR ASSEMBLY
13. INSTALL GENERATOR ASSEMBLY
14. INSTALL VANE PUMP ASSEMBLY
15. INSTALL DRIVE BELT
16. INSTALL RADIATOR ASSEMBLY
17. CONNECT NO. 1 OIL COOLER OUTLET TUBE
18. CONNECT NO. 1 OIL COOLER INLET TUBE
19. CONNECT NO. 2 RADIATOR HOSE
20. CONNECT NO. 1 RADIATOR HOSE
21. INSTALL AIR CLEANER ASSEMBLY
a. Install the air cleaner assembly with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
b. Connect the MAF meter connector and clamp to the air cleaner.
22. INSTALL AIR CLEANER HOSE ASSEMBLY
23. INSTALL V-BANK COVER
24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
25. PERFORM INITIALIZATION
a. Perform initialization

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

26. ADD ENGINE COOLANT
27. CHECK FOR ENGINE COOLANT LEAKS
28. INSTALL NO. 1 ENGINE UNDER COVER
a. Install the engine undercover with the 5 bolts.
29. INSTALL ENGINE REAR UNDER COVER
a. Install the engine undercover with the 8 bolts.