Timing Belt: Service and Repair
TIMING BELT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove the front suspension tower bar.
4. Remove the air pipe.
5. Remove the drive belt.
6. Remove the CKP sensor.
7. Remove the high-tension lead and ignition coil.
8. Remove the spark plug.
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Inspect the air gap between the crankshaft position sensor.
12. Inspect the engine oil level.
13. Start the engine, and inspect the following and adjust if necessary:
^ Pulley and belt for runout or contact
^ Engine oil and engine coolant for leakage
^ Ignition timing
^ Operation of auxiliary parts
Oil Pipe Removal Note
Caution:
^ If the engine oil get spilled on other components, it may cause malfunction of the components. Cover with a rag to prevent engine oil from spilling whenever removing the oil pipe.
Note:
^ Keep the oil pipe of engine side with the bolt removed.
Pulley Lock Bolt Removal/Installation Note
1. Install SST on the pulley boss to prevent the crankshaft from rotating.
Timing Belt Removal Note
1. Install the pulley boss on the crankshaft to temporarily tighten with pulley lock bolt.
2. Rotate the crankshaft in the appropriate direction to meet the timing mark.
Note:
^ It is preferable that the positioning pins of the pulley boss are just above the timing marks.
3. Loosen the tensioner lock bolt and temporarily tighten the tensioner lock bolt while pulling the tensioner to the left.
Caution:
^ The following will damage the belt and shorten its life; forcefully twisting it, turning it inside out, or allowing oil or grease on it.
Note:
^ Mark the timing belt rotation on the belt for proper reinstallation.
Tensioner and Tensioner Spring Installation Note
1. Measure the tensioner spring free length.
^ If not within the specification, replace the tensioner spring.
Free length 59.2 mm (2.31 inch)
2. Install the tensioner.
3. Install the tensioner spring with the damper rubber closing face on the right side.
4. Temporarily secure the tensioner with the spring fully extended.
Timing Belt Installation Note
1. Verify that the timing belt pulley mark and camshaft pulley marks are aligned with the timing marks as shown.
2. Install the timing belt so that there is no looseness at the idler side and between the camshaft pulleys.
3. Install the pulley boss and pulley lock bolt.
4. Turn the crankshaft clockwise 1 and 5/6 times, and align the timing belt pulley mark with the tensioner set mark for proper timing belt tension adjustment.
5. Hold the crankshaft using the SST, and remove the pulley lock bolt and the pulley boss.
6. Verify that the timing belt pulley mark is aligned with the tensioner set mark.
7. Loosen the tensioner lock bolt to apply tension to the timing belt.
8. Tighten the tensioner lock bolt.
Caution:
^ Avoid the tensioner from moving with the tensioner lock bolt as it is turned.
9. Install the pulley boss and the pulley lock bolt.
10. Turn the crankshaft 2 and 1/6 times, and face the pin on the pulley boss straight up.
11. Verify that the camshaft pulley marks are aligned with the timing marks as shown.
^ If not, repeat from "Timing Belt Removal Note".
Note:
^ It is preferable that the positioning pins of the pulley boss are just above the timing marks.
12. Measure the belt deflection at the point shown in the figure.
^ If not as specified, repeat from Step 4.
Timing belt deflection 8.5 - 11.5 mm (0.35 - 0.45 inch)
Timing Belt Cover Installation Note
1. Tighten the timing belt cover bolts in the numerical order shown in the figure.
Cylinder Head Cover Installation Note
1. Apply liquid gasket of TB1207B or SH780 to the portions shown in the figure.
2. Temporarily tighten the cylinder head cover bolt on the portion A shown in the figure.
Caution:
^ Do not damage the O-ring while installing the OCV case. If the O-ring of the OCV adapter on camshaft cap is damaged, it may cause hydraulic leakage.
3. Tighten the cylinder head cover bolts for several times in the numerical order shown in the figure.
Oil Control Valve (OCV) Case Installation Note
1. Tighten the OCV case bolts for several times in the numerical order shown in the figure.
Caution:
^ Do not damage the O-ring while installing the OCV case. If the O-ring of the OCV adapter on camshaft cap is damaged, it may cause hydraulic leakage.
Oil Pipe Installation Note
Caution:
^ Perform the following procedures so that there is no load applied on each connection part while installing the oil pipe as it may cause oil leakage.
1. Hold the frame of the OCV filter and install the OCV so as to align with the projected part on flange end of the oil pipe.
2. Apply engine oil to the new washer.
3. Temporarily install the upper and side oil pipe and position the oil pipe.
4. Tighten the oil pipe bolts for several times in the numerical order shown in the figure.
5. Tighten the oil pipe bolts for several times on the portion A shown in the figure.
Tightening torque 7.8 - 10.8 Nm (80 - 110 kg.cm, 70 - 95 inch lbs.)
6. Temporarily tighten the oil pipe bolt on the portion B shown in the figure.
Tightening torque 2.9 - 6.9 Nm (26 - 61 kg.cm, 26 - 61 inch lbs.)
7. Temporarily tighten the oil pipe bolt on the portion C shown in the figure.
Tightening torque 11.8 - 17.6 Nm (1.2 - 1.8 kg.m, 8.7 - 13 ft. lbs.)
8. Tighten the oil pipe bolts for several times in the numerical order shown in the figure.
Tightening torque
No. 1, 2, 3, 4, 7: 7.8 - 10.8 Nm (80 - 110 kg.cm, 70 - 95 inch lbs.)
No. 5: 15.7 - 23.5 Nm (1.6 - 2.3 kg.m, 11.6 - 17.3 ft. lbs.)
No. 6: 34.4 - 47.0 Nm (3.5 - 4.7 kg.m, 25.4 34.6 ft. lbs.)