Timing Belt: Service and Repair

TIMING BELT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

REMOVAL
1. DRAIN ENGINE COOLANT
2. SEPARATE BATTERY NEGATIVE TERMINAL
3. REMOVE V-BANK COVER SUB-ASSEMBLY
(a) Remove the 2 nuts and V-bank cover sub-assembly.

4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE ENGINE ROOM SIDE COVER LH
6. REMOVE AIR CLEANER HOSE ASSEMBLY
7. REMOVE RADIATOR SUPPORT SEAL UPPER
(a) Remove the 11 clips and radiator support seal upper.

8. REMOVE FAN AND GENERATOR V BELT

9. REMOVE FAN WITH FLUID COUPLING
(a) Unfasten each clip and the 2 hose clamps, and then separate the 2 oil cooler hoses from the fan shroud.
(b) Remove the 3 bolts and separate the fan shroud from the radiator.
(c) Remove the 4 nuts and separate the fan with fluid coupling from the engine.
(d) Remove the fan shroud and fan with fluid coupling together from the vehicle.
(e) Remove the fan pulley.

10. SEPARATE VANE PUMP ASSEMBLY
(a) Disconnect the vacuum hose.
(b) Remove the nut, 2 bolts and vane pump assembly.

HINT: Hang up the hoses instead of detaching.

11. REMOVE GENERATOR ASSEMBLY

12. SEPARATE COMPRESSOR
(a) Disconnect the compressor connector.
(b) Remove the nut, 3 bolts, compressor stay and compressor.

HINT: Hang up the hoses instead of detaching.

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

14. REMOVE OIL COOLER PIPE
(a) Disconnect the 3 hoses.
(b) Remove the bolt, nut and oil cooler pipe.

15. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY LH
(a) Remove the grommet and separate the cam position sensor connector from the No. 3 timing belt cover sub-assembly LH.
(b) Remove the 4 bolts and No. 3 timing belt cover subassembly LH.

16. REMOVE NO. 2 TIMING CHAIN OR BELT COVER
(a) Remove the nut, 3 bolts and No. 2 timing belt cover.

17. REMOVE NO. 2 TIMING BELT COVER SUBASSEMBLY
(a) Remove the 2 bolts and No. 2 timing belt cover subassembly.

18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the bolt, 2 nuts and V-ribbed belt tensioner.

19. REMOVE FAN BRACKET SUB-ASSEMBLY
(a) Remove the 2 nuts, 2 bolts and fan bracket subassembly.

20. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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

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

21. REMOVE TIMING BELT NO. 1 COVER
(a) Remove the 4 bolts and timing belt cover.

22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Remove the No. 1 crankshaft position sensor plate.

23. REMOVE TIMING BELT

(a) If reusing the timing belt, check the installation marks on the timing belt.
(1) Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part.
(b) Set the No. 1 cylinder to approximately 50° 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 complete revolution (360°).

(3) Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 50°.

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.

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

INSTALLATION
1. INSTALL TIMING BELT
(a) Check the No. 1 timing belt idler and No. 2 timing belt idler.
(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 timing belt.
(2) Turn the pulley, and check that the water pump bearing moves smoothly.
If necessary, replace the water pump.
(c) Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No. 1 idler and No. 2 idler, and keep them clean.

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

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

HINT:
By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:
1/2 teeth turn for the left bank camshaft timing pulley
1 tooth turn for the right bank camshaft timing pulley

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

(e) Install the timing belt.
(1) Remove any oil or water on each pulley, and keep them clean.

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

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

(f) 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 lbf) of pressure.
(2) Align the holes of the push rod and housing, and 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.

(g) Install the belt tensioner.
(1) Temporarily install the belt tensioner with the 2 bolts.
(2) Alternately tighten the 2 bolts.
Torque: 26 N*m (270 kgf*cm, 19 ft.*lbf)
(3) Using pliers, remove the 1.27 mm hexagon wrench from the chain tensioner.
(h) Check the valve timing.

(1) Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.

NOTICE: Always turn the crankshaft pulley clockwise.

(2) Check that each pulley is aligned with each timing mark as shown in the illustration. If the timing marks are not aligned, remove the timing belt and reinstall it.
(3) Remove the crankshaft damper bolt.

2. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Install the sensor plate as shown in the illustration.

NOTICE: Take care not to install it in a wrong direction.

3. INSTALL TIMING BELT NO. 1 COVER
(a) Install the timing belt cover with the 4 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

4. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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

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

5. INSTALL FAN BRACKET SUB-ASSEMBLY
(a) Install the idler pulley with the 2 bolts and 2 nuts.
Torque:
For 12 mm head 16 N*m (160 kgf*cm, 12 ft.*lbf)
For 14 mm head 32 N*m (326 kgf*cm, 24 ft.*lbf)

HINT:
Each bolt length is as follows:
106 mm (4.17 in.) for 12 mm head (A)
114 mm (4.49 in.) for 14 mm head (B)

6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 N*m (160 kgf*cm, 11 ft.*lbf)

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

7. INSTALL NO. 2 TIMING BELT COVER SUBASSEMBLY
(a) Install the timing belt cover and fit the claws and pins into each part.
(b) Install the timing belt cover with the 2 bolts.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)

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

8. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH
(a) Install the timing belt cover sub-assembly with the 4 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
(b) Install the camshaft position sensor connector and grommet to the timing belt cover.

9. INSTALL NO. 2 TIMING CHAIN OR BELT COVER
(a) Install the timing chain or belt cover with the nut and 3 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

10. INSTALL OIL COOLER PIPE
(a) Install the oil cooler pipe with the bolt and nut.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
(b) Connect the 3 hoses.

11. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley and cover plate with the bolt.
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)

12. INSTALL COMPRESSOR
(a) Install the compressor with the stay, nut and 3 bolts.
Torque:
Bolt 47 N*m (475 kgf*cm, 34 ft.*lbf)
Nut 25 N*m (255 kgf*cm, 18 ft.*lbf)

13. INSTALL GENERATOR ASSEMBLY
14. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly with the nut and 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

15. INSTALL FAN WITH FLUID COUPLING
(a) Install the fan pulley to the engine.
(b) Put the fan with fluid coupling and fan shroud together into the engine room.
(c) Install the fan shroud with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(d) Install the fan with fluid coupling with the 4 nuts.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)

16. INSTALL FAN AND GENERATOR V BELT
17. INSTALL RADIATOR SUPPORT SEAL UPPER
18. INSTALL AIR CLEANER HOSE ASSEMBLY
19. INSTALL ENGINE ROOM SIDE COVER LH
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Install the V-bank cover sub-assembly with the 2 nuts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

22. ADD ENGINE COOLANT
23. CHECK FOR ENGINE COOLANT LEAKS