Timing Belt: Service and Repair

TIMING BELT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

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 and seat belt pretensioner activation.

2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE ENGINE ROOM SIDE COVER LH
5. REMOVE NO. 1 AIR CLEANER INLET
(a) Remove the bolt and No. 1 air cleaner inlet.

6. DRAIN ENGINE COOLANT
7. REMOVE V-BANK COVER
8. REMOVE INTAKE AIR CONNECTOR PIPE
9. REMOVE ENGINE UNDER COVER
10. DISCONNECT RADIATOR HOSE INLET
11. DISCONNECT RADIATOR HOSE OUTLET
12. DISCONNECT NO. 1 OIL COOLER INLET TUBE
13. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE
14. REMOVE AIR CLEANER ASSEMBLY
15. REMOVE RADIATOR ASSEMBLY
(a) Removal the radiator.

16. REMOVE FAN AND GENERATOR V-BELT
17. REMOVE GENERATOR ASSEMBLY
18. REMOVE NO. 1 IDLER PULLEY BRACKET SUBASSEMBLY

(a) Remove the bolt, pulley plate and idler pulley.

(b) Remove the 2 bolts and bracket.

19. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY
(a) Remove the 3 bolts, nut, stay and wire bracket, and disconnect the cooler compressor.

HINT: If is not necessary to completely remove the compressor. With the low pressure and high pressure hoses connected to the compressor, hang the compressor (with the magnetic clutch) on the vehicle body with a rope.

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

21. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY LH

(a) Remove the cap nut and disconnect the No. 3 water by-pass pipe from the timing belt cover.
(b) Disconnect the 2 water by-pass hoses from the No. 3 water by-pass pipe.

(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.

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

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

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

25. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the 2 bolts, 2 nuts and idler pulley.

26. 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)

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

28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
29. 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 the timing belt disengaged, the crankshaft damper must be at the correct angle to avoid damage in a later step.

(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 No. 1 timing belt idler, and remove the belt.

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 allow the 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 these points:

(a) Premature parting
(1) Check for proper installation.
(2) 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 and water pump.
(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 or the belt teeth, check the 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 TIMING BELT TENSIONER

(a) Visually check the seal portion of on the tensioner for oil leakage.

NOTICE:
^ If there is only the faint trace of oil on the push rod, the tensioner does not need to be replaced.
^ If leakage is found, replace the tensioner.

(b) Hold the tensioner with both hands and push the push rod strongly as shown in the illustration to check that it does not move.
If the push rod moves, replace the tensioner.

NOTICE: Never hold the tensioner push rod facing downward.

(c) Measure the protrusion of the push rod from the housing end.
Protrusion: 9.5 to 10.5 mm (0.374 to 0.413 in.)
If the protrusion is not as specified, replace the tensioner.

3. INSPECT TIMING BELT IDLER
(a) Visually check the seal portion of the idler for oil leakage.
If leakage is found, replace the idler.
(b) Check that the idler turns smoothly.
If necessary, replace the idler.

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 idler.
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 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 pullet. 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 idler.
(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 No. 1 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 lbf) 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 N*m (265 kgf*cm, 19 ft.*lbf)
(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 NO. 1 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 N*m (76 kgf*cm, 66 in.*lbf)

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

5. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler with the 2 bolts and 2 nuts.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) for 12 mm head
Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for 14 mm head
Bolt length:
106 mm (4.17 in.) for 12 mm head bolt A
114 mm (4.49 in.) for 14 mm head bolt B

6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the belt tensioner with the bolt and 2 nuts.
Torque: 15.5 N*m (158 kgf*cm, 11 ft.*lbf)

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

7. INSTALL NO. 2 TIMING BELT COVER SUBASSEMBLY
(a) Set the No. 2 cover by matching the claws and pin with each part.
(b) Install the timing belt cover with the 2 bolts.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)

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

8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley and cover plate with the bolt.

9. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH

(a) Install the gasket to the cover.
(b) Pass the camshaft position sensor wire through the cover hole.
(c) Install the cover with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(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 N*m (76 kgf*cm, 66 in.*lbf)

10. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY RH
(a) Install the gasket to the cover.
(b) Install the cover with the cap nut and 3 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

11. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY
(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 N*m (500 kgf*cm, 36 ft.*lbf) for bolts
29 N*m (295 kgf*cm, 21 ft.*lbf) for nuts

12. INSTALL NO. 1 IDLER PULLEY BRACKET SUBASSEMBLY

(a) Install the bracket with the 2 bolts.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

(b) Install the idler pulley and pulley plate with the bolt.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

13. INSTALL GENERATOR ASSEMBLY
14. INSTALL FAN AND GENERATOR V-BELT
15. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator.

16. CONNECT NO. 1 OIL COOLER OUTLET TUBE
17. CONNECT NO. 1 OIL COOLER INLET TUBE
18. CONNECT RADIATOR HOSE OUTLET
19. CONNECT RADIATOR HOSE INLET

20. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the MAF meter connector and clamp to the air cleaner.

21. INSTALL NO. 1 AIR CLEANER INLET
(a) Install the No. 1 air cleaner inlet and bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

22. INSTALL INTAKE AIR CONNECTOR PIPE
23. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

24. REMOVE ENGINE ROOM SIDE COVER LH
25. REMOVE ENGINE ROOM SIDE COVER RH
26. REMOVE COOL AIR INTAKE DUCT SEAL
27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
28. PERFORM INITIALIZATION
(a) Perform initialization.

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

29. ADD ENGINE COOLANT
30. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks.

31. INSTALL ENGINE UNDER COVER