Timing Belt: Service and Repair

TIMING BELT REMOVAL AND INSTALLATION







SERVICE POINTS OF REMOVAL
[A] REMOVAL OF COMPRESSOR (A/C) / OIL PUMP (POWER STEERING).
Remove the oil pump and air conditioning compressor (with the hose attached).

NOTE:
- Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal/installation on the engine assembly.





[B] REMOVAL OF CRANKSHAFT PULLEY.
Using special tools, remove the crankshaft pulley from the crankshaft.

CAUTION:
- Use only the specified special tools, or a damaged pulley damper could result.

[C] REMOVAL OF TIMING BELT.





(1) Align the timing marks.

(2) Loosen the center bolt on the tensioner pulley to remove the timing belt.





CAUTION:
- Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.
- The cam of the front bank camshaft lifts the valve by means of the rocker arm, the spring force of the valve will easily turn the sprocket, so be careful not to insert your fingers, etc..

INSPECTION





AUTO TENSIONER
- Check the auto tensioner for possible leaks.
- Check the push rod for cracks.





SERVICE POINTS OF INSTALLATION

[A]INSTALLATION OF AUTO TENSIONER





(1) If the auto tensioner rod is in its fully extended position, reset it as follows.
(1) Keep the auto tensioner level and, in that position, clamp it in the vise with soft jaws.
(2) Push in the rod little by little with the vise until the set hole (A) in the rod is aligned with that (B) in the cylinder.

CAUTION:
- The auto tensioner must be placed at a right angle to the pressing surface of press or vise.
- Push in the rod slowly to prevent the push rod from being damaged.





(3) Insert a wire [1.4 mm (0.055 in.) in diameter] into the set holes.

NOTE:
- The wire should he as stiff as possible (such as piano wire, etc..), and should be bent into the shape of an "L"

(4) Unclamp the auto tensioner from the vise.

(2) Install the auto tensioner.

CAUTION:
- Leave the wire installed in the auto tensioner.

[B] INSTALLATION OF TIMING BELT.





(1) Install the crankshaft pulley and turn the crankshaft sprocket timing mark forward 5 teeth to move the position slightly past No.1 cylinder top dead center.

CAUTION:
- When the camshaft sprocket is turned with No.1 cylinder top dead center, there is a danger that the valve and piston will interfere.





(2) Align the timing mark of the left bank side camshaft sprocket.





(3) Align the timing mark of the right bank side camshaft sprocket and support it not to rotate with a closed wrench.

CAUTION:
- The camshaft sprocket will easily turn because of the valve spring force, so be careful not to insert your fingers, etc..
- If the sprocket on one side of the right bank is turned one full revolution while the sprocket timing marks on the opposite side of the right bank are aligned, the intake and exhaust valves may cause interference.





(4) Check that the camshaft sprocket timing mark of the right bank side is aligned and clamp timing belt with double cups.

CAUTION:
- If the timing belt is reused, install so that the arrow marked on it at the time of removal is pointing in the clockwise direction.

(5) Set the timing belt onto the water pump pulley.





(6) Check that the camshaft sprocket timing mark of the bank side is aligned and clamp the timing belt with double clips.

(7) Set the timing belt onto the idler pulley.





(8) After aligning the crankshaft sprocket timing marks, turn the crankshaft one touch anticlockwise.

(9) Set the timing belt onto the crankshaft sprocket.

(10) Set the timing belt onto the tensioner pulley.





(11) Place the tensioner pulley pin hole so that it is towards the top. Press the tensioner pulley onto the timing belt, and provisionally tighten the fixing bolt.

(12) Align the crankshaft sprocket timing marks.

(13) Check that each of the sprocket timing mark is aligned.

(14) Remove the 4 double clips.

[C] ADJUSTMENT OF TIMING BELT TENSION





(1) After turning the crankshaft a 1/4 turn anticlockwise, Turn it clockwise to the position where the timing marks are aligned.





(2) Loosen the center bolt on the tensioner pulley. Using the special tool and torque wrench, apply tensioning torque to the timing belt and, at the same rime, tighter the center bolt to specification.

Reference value: 9.4 Nm (7ft.lbs.) (Timing belt tensioning torque)

CAUTION:
- When tightening the center bolt, make sure that the tensioner pulley is not rotated together.





(3) Remove the set pin from The auto tensioner. At this time, make sure that the set pin can be easily removed.

(4) Rotate the crankshaft we turns clockwise and leave it as is for five minutes or more. Then, check again that The set pin can be easily removed from, and installed to, The auto tensioner.





NOTE:
- Even if the set pin cannot be easily inserted, The auto Tensioner is normal if its rod protrusion is within specification.

Standard value (A): 3.8 to 4.5 mm (.149 to .177 in.)

If the protrusion is out of specification, repeat steps (1) to (4).

(5) Check again that timing marks on all sprockets are aligned properly.





[D] INSTALLATION OF CRANKSHAFT PULLEY.
Using the special tool, attach the crankshaft pulley to the crankshaft.

CAUTION:
- Use only the specified special tools, otherwise a damaged pulley damper could result.