Timing Belt: Service and Repair

Part 1:

Part 2:

TIMING BELT
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
4. REMOVE VANE PUMP V BELT





5. REMOVE ENGINE MOVING CONTROL ROD
a. Remove the reserve tank cap.
b. Remove the 4 bolts, engine moving control rod and bracket.





6. REMOVE ENGINE MOUNTING STAY NO.2 RH
a. Remove the bolt, engine mounting stay No. 2 and engine mounting bracket No. 2.





7. REMOVE GENERATOR BRACKET NO.2
a. Remove the nut and generator bracket.
8. REMOVE CRANKSHAFT PULLEY





a. Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021





b. Using SST and the pulley bolt, remove the pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

NOTICE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.

9. REMOVE TIMING BELT NO.1 COVER





10. REMOVE TIMING BELT NO.2 COVER
a. Disconnect the 2 engine wire protector clamps from the timing belt No. 3 cover.
b. Remove the 5 bolts and timing belt cover.





11. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 2 bolts, nut and engine mounting bracket RH.
12. REMOVE TIMING BELT GUIDE NO.2
13. REMOVE TIMING BELT
a. Set the No. 1 cylinder to the TDC/compression.





1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
2. Turn the crankshaft clockwise, then align the timing mark of the crankshaft timing pulley with the oil pump body.





3. Check that the timing marks of the camshaft timing pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360°).
4. Remove the crankshaft pulley bolt.





b. If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.





c. Set the No. 1 cylinder to approximately 60° BTDC/compression.
1. Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: If the timing belt is disengaged, having the crankshaft pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.

d. Remove the timing belt tensioner.

NOTICE: Do not reinstall the tensioner with its plunger extended.








e. Remove the timing belt in this order.





14. INSPECT TIMING BELT

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

Check the belt for any defects as shown in the illustrations.
Also, check these points.
a. If the belt tears in a short time:
^ Check if the belt is installed properly.
^ Check if the timing cover gasket is damaged and if it is installed properly.
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 water pump.
d. If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley.
e. If there is noticeable wear on the belt teeth:
^ Check the timing cover for damage.
^ Check that the gasket has been installed correctly.
^ Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.
15. INSTALL TIMING BELT
a. Remove any oil or water on the pulleys, then keep them clean.

NOTICE:
^ If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
^ Only wipe the pulleys; do not use any cleaning agent.

b. Check the idler pulleys.
1. Check that the idler pulley turns smoothly.
2. Visually check the seal portion of the idler pulley for oil leakage.
c. Check the water pump.
1. Turn the pulley, then check that water pump bearing moves smoothly and does not make a noise.
2. Visually check the drain hole for coolant leakage.
d. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.





e. Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: To prevent contact of the piston head with the valve head, set the crankshaft pulley at the 60° BTDC/compression position.





f. Using SST, turn the timing pulleys, then align the timing marks of the timing pulleys with the timing belt No. 3 cover.
SST 09960-10010 (09962-01000, 09963-01000)





g. Turn the crankshaft, then align the timing mark of the crankshaft timing pulley with the oil pump body.





h. Align the front mark on the timing belt so it faces forward.
i. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
j. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.








k. Install the timing belt in this order.
16. INSTALL TIMING BELT TENSIONER ASSEMBLY
a. Set the timing belt tensioner upright on the press.





b. Slowly press in the push rod.

NOTICE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbs.) to the rod.

c. Align the holes of the push rod and housing, then pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
d. Release the press.
e. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)

NOTICE: Be sure to tighten the bolts uniformly. Installing the tensioner at an angle may cause failure of its proper operation.

f. Remove the 1.5 mm hexagon wrench from the tensioner.





g. Turn the crankshaft 2 revolutions slowly, then align the timing mark of the crankshaft timing pulley with the oil pump body.

NOTICE: Always turn the crankshaft clockwise.





h. Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall it.
i. Remove the crankshaft pulley bolt.





17. INSTALL TIMING BELT GUIDE NO.2
a. Install the timing belt guide with the cup side facing the engine front.





18. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the engine mounting bracket RH with the 2 bolts and nut.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
19. INSTALL TIMING BELT NO.2 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace of water intrusion when checking visually, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
20. INSTALL TIMING BELT NO.1 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace of water intrusion when checking visually, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
c. Install the 2 engine wire protector clamps to the timing belt No. 3 cover.





21. INSTALL CRANKSHAFT PULLEY
a. Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
b. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 Nm (2250 kgf-cm, 162 ft. lbs.)
22. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)





23. INSTALL ENGINE MOUNTING STAY NO.2 RH
a. Install the engine mounting stay No. 2 and engine mounting bracket No. 2 with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





24. INSTALL ENGINE MOVING CONTROL ROD
a. Install the engine moving control rod and bracket with the 4 bolts.
Torque:
64 Nm (653 kgf-cm, 47 ft. lbs.) for bolt A
23 Nm (235 kgf-cm, 17 ft. lbs.) for bolt B
25. INSTALL VANE PUMP V BELT
26. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
27. INSPECT DRIVE BELT DEFLECTION AND TENSION
28. INSTALL FRONT WHEEL RH