Timing Belt: Service and Repair
REPLACEMENT1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE AIR CLEANER INLET NO.1
3. DRAIN ENGINE COOLANT
4. REMOVE V-BANK COVER
5. REMOVE INTAKE AIR CONNECTOR PIPE
6. REMOVE ENGINE UNDER COVER
7. DISCONNECT RADIATOR HOSE NO.1
8. DISCONNECT RADIATOR HOSE NO.2
9. DISCONNECT OIL COOLER INLET TUBE NO.1
10. DISCONNECT OIL COOLER OUTLET TUBE NO.1
11. REMOVE AIR CLEANER ASSEMBLY
12. REMOVE RADIATOR ASSEMBLY
13. REMOVE FAN AND GENERATOR V BELT
14. REMOVE VANE PUMP ASSEMBLY
a. Remove the 2 bolts, nut and pump.
HINT: The pump should be removed with the hoses connected. Then hang with a rope or wire on the vehicle body's side.
15. REMOVE GENERATOR ASSEMBLY
16. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the 3 bolts, nut, stay and wire bracket, and disconnect the cooler compressor.
HINT: The cooler compressor (together with magnetic clutch) should be disconnected with the low-pressure and high-pressure hoses connected, and then hung with a rope or wire on the vehicle body's side.
17. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.3 RH
a. Disconnect the 2 PS air hoses from the clamp on the timing belt cover.
b. Remove the cap nut, 3 bolts, timing belt cover and gasket.
18. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Remove the cap nut and disconnect the water by-pass pipe No. 3 from the timing belt cover.
b. Disconnect the 2 water by-pass hoses from the water bypass pipe No. 3.
c. Disconnect the engine wire from the 2 wire clamps.
d. Disconnect the camshaft position sensor connector.
e. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
f. Remove the wire grommet from the timing belt cover.
g. Remove the 4 bolts.
h. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
i. Disconnect the wire clamp for the sensor from the timing belt cover.
j. Remove the connector holder from the sensor connector.
k. Remove the timing belt cover.
19. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and timing belt cover.
20. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and belt tensioner.
21. REMOVE IDLER PULLEY ASSEMBLY
a. Remove the 2 bolts, 2 nuts and idler pulley.
22. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Using SST, remove the damper bolt.
SST 09213-70011, 09330-00021
b. Using SST, remove the damper.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
23. REMOVE TIMING BELT NO.1 COVER
a. Remove the 4 bolts and cover.
24. REMOVE CRANKSHAFT POSITION SENSOR PLATE
25. REMOVE TIMING BELT
a. 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.
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 revolution (360°).
3. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 45°.
NOTICE: With timing belt disengaged: The crankshaft damper must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and then the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and be damaged.
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 bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise.
SST 09960-10010 (09962-01000, 09963-00350)
e. Disconnect the belt from the timing belt idler No. 1, and remove the belt.
26. INSTALL TIMING BELT
a. Check the belt idler No. 1 and No. 2.
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, idler No. 1 and No. 2. 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 wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned.
HINT: Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.
Camshaft timing pulley of LH bank: 1/2 of a tooth
Camshaft timing pulley of RH bank: 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 idler No. 2.
7. Connect the belt to the camshaft timing pulley (LH bank). 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 bank). Align the installation mark on the belt with the timing mark of the camshaft timing pulley.
10. Connect the timing belt to the idler No. 1.
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 timing marks do not align, remove the belt and reinstall it.
3. Remove the crankshaft damper bolt.
27. INSTALL CRANKSHAFT POSITION SENSOR PLATE
a. Install the crankshaft position sensor plate as shown in the illustration.
NOTICE: Be careful of the installation direction.
28. INSTALL TIMING BELT NO.1 COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
29. 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, 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)
30. INSTALL IDLER PULLEY ASSEMBLY
a. Install the idler with the 2 bolts and 2 nuts.
Torque:
16 Nm (163 kgf-cm, 12 ft. lbs.) for 12 mm head
32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head
Bolt length:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)
31. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 15.5 Nm (158 kgf-cm, 11 ft. lbs.)
HINT: Use bolts that arm 106 mm (17 inch) in length.
32. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Set the cover No. 2 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.
33. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Install the gasket to the cover.
b. Run 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 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.
i. Connect the 2 water by-pass hoses as shown in the illustration.
j. Install the No. 3 water by-pass pipe to the cover with the cap nut.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
34. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 RH
a. Install the gasket to the cover.
b. Install the cover with the cap nut and 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
c. Install the 2 PS air hoses to the clamp on the cover.
35. CONNECT COMPRESSOR AND MAGNETIC CLUTCH
a. Set the cooler compressor to the engine. Then install the stay, wire bracket, 3 bolts and nut to connect the cooler compressor.
Torque:
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolts
29 Nm (295 kgf-cm, 21 ft. lbs.) for nuts
36. INSTALL GENERATOR ASSEMBLY
37. INSTALL VANE PUMP ASSEMBLY
a. Install the pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque:
39.2 Nm (400 kgf-cm, 29 ft. lbs.) for bolts
43.1 Nm (439 kgf-cm, 32 ft. lbs.) for nut
38. INSTALL FAN AND GENERATOR V BELT
39. INSTALL RADIATOR ASSEMBLY
40. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
41. INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
42. INSTALL INTAKE AIR CONNECTOR PIPE
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
43. INSTALL V-BANK COVER
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
44. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
45. PERFORM INITIALIZATION
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
46. ADD ENGINE COOLANT
47. CHECK FOR ENGINE COOLANT LEAKS
48. INSTALL ENGINE UNDER COVER