Timing Belt: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE RADIATOR ASSEMBLY
4. REMOVE DRIVE BELT





5. REMOVE PS PUMP AND FRONT BRACKET
a. Remove the 3 bolts, plate washer and pump front bracket.
b. Disconnect the vane pump from the bracket.
6. REMOVE NO.3 TIMING BELT COVER
Using a 5 mm hexagon wrench, remove the 4 bolts, oil filler cap, timing belt cover and gasket.





7. REMOVE NO.2 TIMING BELT COVER
Using a 5 mm hexagon wrench, remove the 3 bolts, timing belt cover and gasket.





8. REMOVE DRIVE BELT TENSIONER
Remove the 3 bolts and tensioner.

NOTICE: Be careful not to drop the bolts inside the timing belt cover.





9. LOOSEN CRANKSHAFT PULLEY BOLT
Using SST, loosen the pulley bolt.
10. SET NO.1 CYLINDER TO APPROXIMATELY 60°/ BTDC COMPRESSION





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

NOTICE: Always turn the crankshaft clockwise.

b. Check that the timing marks (TDC mark) of the camshaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover.
If not, turn the crankshaft 1 revolution (360°).





c. Turn the crankshaft pulley 60° counterclockwise to place the sub timing mark (60° mark BTDC) on the crankshaft pulley at the timing mark "0" position of the No.1 timing belt cover.

NOTICE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulleys (steps 11 to 17), thus resulting damage. So, always set the crankshaft pulley at the correct angle.





d. Check that the dot marks (60° mark BTDC) of the cam shaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover.
e. Remove the crankshaft pulley bolt.

NOTICE: Do not turn the crankshaft pulley.





11. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS

HINT: (Reusing timing belt): Place matchmarks on the timing belt and camshaft timing pulleys as shown in the illustration.





a. Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot.
b. Disconnect the timing belt from the camshaft timing pulleys.





12. REMOVE EXHAUST CAMSHAFT TIMING PULLEY
Using SST, remove the bolt and timing pulley.
13. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
14. REMOVE THROTTLE BODY AND INTAKE AIR CONNECTOR ASSEMBLY
15. REMOVE NO.1 CYLINDER HEAD COVER





a. Using a 5 mm hexagon wrench, remove the bolts, and disconnect the engine wire protector from the No.2 cylinder head cover.
b. Remove the nut, and disconnect the engine wire protector from the intake manifold.
c. Remove the 2 bolts, and disconnect the high tension cords with the clamp from the No.2 cylinder head.





d. Remove the 2 nuts from the No. 1 cylinder head cover.
e. Using a torx socket (E5), remove the 2 stud bolts.
f. Remove the 6 bolts, No. 1 cylinder head cover and gasket.
16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE





17. DISCONNECT NO.1 OIL PIPE
Remove the bolt, union bolt, oil control valve filter and 2 gaskets, and disconnect the No.1 oil pipe from the No.3 camshaft bearing cap.
18. REMOVE VVT-i (INTAKE CAMSHAFT TIMING) PULLEY





NOTICE:
- The 5 bolts shown in the illustration determine the backlash of the gear in the timing pulley, so do not re move them.
- If any of the 5 bolts are removed, install a new camshaft timing pulley assembly.
- When removing the straight screw plug, follow the prescribed procedure in order to avoid spilling oil on the timing system parts.

a. Rotate the VVT-i pulley from left to right 2 to 3 times within its range of movement (30°) and use a waste cloth to collect the oil from the camshaft timing oil control valve installation hole.

NOTICE: Approximately 20 cc (1.2 cu inch) of oil will be ejected, so take care not to spill it.





b. Holding the hexagon portion of camshaft with a wrench.
c. Using a 14 mm hexagon wrench, remove the straight screw plug and seal washer.

NOTICE: Some oil may spill, so put a waster cloth below the plug white doing the operation.

d. Using a 10 mm hexagon wrench, and remove the set bolt and VVT-i pulley.
e. Remove the wrench.





19. REMOVE CRANKSHAFT PULLEY
Using SST and bolt (diameter: 8 mm, pitch: 15 mm), remove the crankshaft pulley
Bolt: Part No. 90119-18001

NOTICE: Do not turn the crankshaft pulley.

20. REMOVE NO.1 TIMING BELT COVER
Remove the 5 bolts, timing belt cover and gasket.
21. REMOVE TIMING BELT GUIDE





22. REMOVE TIMING BELT

HINT: (When reusing timing belt): Draw an arrow on the timing belt in the direction of engine revolution, and place matchmarks on the timing belt and crankshaft timing pulley.





23. REMOVE IDLER PULLEY
Using a 10 mm hexagon wrench, remove the pivot bolt, plate washer and idler pulley.





24. REMOVE CRANKSHAFT TIMING PULLEY
a. Remove the bolt and timing belt plate.
b. Remove the crankshaft timing pulley.
c. If the pulley cannot be removed by hand, use SST and bolt (diameter: 8 mm, pitch: 1.5 mm) to remove the crankshaft timing pulley.
Bolt: Part No. 90119-18001

NOTICE:
- Do not scratch the sensor part the crankshaft timing pulley.
- 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 come into 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 the following 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 to see if either camshaft is locked.
c. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock.
d. 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 check gasket has been installed correctly and for foreign material on the pulley teeth.
If necessary, replace the timing belt.





2. INSPECT IDLER PULLEY
a. Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
b. Check the turning smoothness of the idler pulley.
If necessary, replace the idler pulley.
3. INSPECT DRIVE BELT TENSIONER
Check the turning smoothness of the tensioner.
If necessary, replace the tensioner.
4. INSPECT TIMING BELT TENSIONER





a. Visually check 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 tensioner.





b. Hold the tensioner with both hands and push the push rod strongly against the floor or wall to check that it doesn't move. if the push rod moves, replace the tensioner.





c. Measure the protrusion of the push rod from the housing end.
Protrusion: 8.0 - 8.8 mm (0.315 - 0.346 inch)
If the protrusion is not as specified, replace the tensioner.

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





b. Slide on the timing pulley facing the flange side inward.

NOTICE: Do not scratch the sensor part of the crankshaft timing pulley.





c. Install the timing belt plate with the bolt.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)





2. INSTALL IDLER PULLEY
a. Apply adhesive to 2 or 3 threads 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 pulley with the pivot bolt.
Torque: 35 Nm (350 kgf-cm, 26 ft. lbs.)
c. Check that the pulley bracket moves smoothly.
3. TEMPORARILY INSTALL TIMING BELT

NOTICE: The engine should be cold.





a. Use the crankshaft pulley bolt to turn the crankshaft, and align the dot mark on the crankshaft timing pulley and the timing mark on the oil pump body.
b. Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean.





c. Install the timing belt on the crankshaft timing pulley and idler pulley.

HINT: When reusing timing belt: Align the matchmarks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.





4. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
5. INSTALL NO.1 TIMING BELT COVER
a. Install the gasket to the timing belt cover.
b. Install the timing belt cover with the 5 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)





6. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Check that the sub timing mark (60° mark BTDC) of the crankshaft pulley is aligned with the timing mark "0" of the No.1 timing belt cover.

HINT: At this time, the crankshaft pulley set key groove and the timing mark (TDC mark) of the crankshaft pulley are as shown in the illustration.

c. Temporarily install the pulley bolt.
7. INSTALL VVT-i (INTAKE CAMSHAFT TIMING) PULLEY





a. Align the camshaft knock pin with the VVT-i pulley, and push the VVT-i pulley by hand until you feel it touch the bottom.





b. Check that the outer circumference of the VVT-i pulley easily rotates through 30°.





c. Holding the hexagon portion of the camshaft with a wrench.
d. Using a 10 mm hexagon wrench, and the set bolt.
Torque: 81 Nm (810 kgf-cm, 60 ft. lbs.)
e. Using a 14 mm hexagon wrench, install the straight screw plug with the seal washer to the set bolt.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
f. Align the dot mark on the camshaft timing pulley with the timing mark of the No.4 timing belt cover.
g. Remove the wrench.





8. CONNECT NO.1 OIL PIPE
a. Install the union bolt to the oil control valve filter.

NOTICE: In case of touching the filter, avoid holding the mesh part and holding the frame part.

b. Install the oil pipe with 2 new gasket and the union bolt to the No.3 camshaft bearing cap.
Torque: 55 Nm (550 kgf-cm, 41 ft. lbs.)
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
10. INSTALL NO.1 CYLINDER HEAD COVER





a. Install the cylinder head and gasket with the 6 bolts.
Torque: 8.5 Nm (85 kgf-cm, 75 inch lbs.)
b. Using a torx socket (E5), install the 2 stud bolts.
Torque: 8.5 Nm (85 kgf-cm, 75 inch lbs.)
c. Install the 2 nuts to the 2 stud bolts.
Torque: 8.5 Nm (85 kgf-cm, 75 inch lbs.)
d. Install the high tension cords and clamps with the 2 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)





e. Using a 5 mm hexagon wrench, install the engine wire protector with the bolt and nut.
11. INSTALL THROTTLE BODY AND INTAKE AIR CONNECTOR ASSEMBLY
12. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
13. INSTALL EXHAUST CAMSHAFT TIMING PULLEY
a. Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley.
b. Slide the timing pulley on the camshaft, facing the front mark forward.





c. Using SST, install the pulley bolt.
Torque: 81 Nm (810 kgf-cm, 60 ft. lbs.)





d. Using SST, align the dot mark on the camshaft timing timing pulley with the timing mark of the No.4 timing belt cover.
14. CONNECT TIMING BELT TO CAMSHAFT TIMING PULLEYS





HINT:
- When reusing timing belt: Check that the matchmark on the timing belt matches the end of the No.1 timing belt cover.
If the matchmark does not align, shift the meshing of the timing belt and crankshaft timing pulley until they align.
- Align the matchmarks of the timing belt and camshaft timing pulleys.





a. Remove any oil or water on the camshaft timing pulley, and keep it clean.
b. Install the timing belt, checking the tension between the crankshaft timing pulley and intake camshaft timing pulley.
15. 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 force.





b. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted.
c. Release the press.





d. Install the dust boot onto the tensioner.
16. INSTALL TIMING BELT TENSIONER





a. Temporarily install the tensioner with the 2 bolts.
b. Alternately tighten the 2 bolts.
Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.)





c. Remove the 1.5 mm hexagon wrench from the tensioner with pliers.
17. CHECK VALVE TIMING





a. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.

NOTICE: Always turn the crankshaft clockwise.





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





18. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST, install the pulley bolt.
Torque: 330 Nm (3,300 kgf-cm, 243 ft. lbs.)
19. INSTALL DRIVE BELT TENSIONER
Install the tensioner with the 3 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)

NOTICE: Be careful not to drop the bolts inside the timing belt cover.

20. INSTALL NO.2 TIMING BELT COVER
a. Install the gasket on the timing belt cover.
b. Using a 5 mm hexagon wrench, install the timing belt cover with the 3 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
21. INSTALL NO.3 TIMING BELT COVER
a. Install the gasket on the timing belt cover.
b. Using a 5 mm hexagon wrench, install the timing belt cover with the 4 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
c. Install the oil filler cap.





22. INSTALL PS PUMP AND FRONT BRACKET
a. Temporarily install the vane pump to the bracket.
b. Install the plate washer and front bracket with the 3 bolts.
Torque:
58 Nm (590 kgf-cm, 43 ft. lbs.) for A bolts
52 Nm (530 kgf-cm, 38 ft. lbs.) for B bolt
23. INSTALL DRIVE BELT
24. INSTALL RADIATOR ASSEMBLY
25. FILL ENGINE WITH COOLANT
26. START ENGINE CHECK FOR LEAKS
27. INSTALL ENGINE UNDER COVER
28. ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
29. RECHECK ENGINE COOLANT LEVEL