Timing Belt: Service and Repair
REMOVAL1. CRANKSHAFT PULLEY AND BELT COVER
1. Remove V-belt.
2. Remove pulley bolt. To lock crankshaft, use Special Tool 499977000.
3. Remove crankshaft pulley.
4. Remove left-hand belt cover.
5. Remove right-hand belt cover and plate CP-belt cover (TURBO model).
6. Remove front belt cover.
2. TIMING BELT
1. If alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows:
(a) Turn crankshaft, and align alignment marks on crankshaft sprocket, and left and right camshaft sprockets with notches of belt cover and cylinder block.
(b) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets use special tool CRANKSHAFT SOCKET (499967500)
2. Loosen tensioner adjuster mounting bolts.
3. Remove belt idler.
4. Remove belt idler No.2
5. Remove timing belt.
3. BELT TENSIONER AND IDLER
1. Remove belt idler.
2. Remove belt tensioner and spacer.
3. Remove belt tension adjuster.
4. SPROCKET
1. Remove left-hand camshaft sprocket.
2. Remove right-hand camshaft sprocket. To lock camshaft, use CAMSHAFT SPROCKET WRENCH.
3. Remove crankshaft sprocket.
4. Remove left-hand belt cover No.2.
5. Remove right-hand belt co
5. WATER AND OIL PUMP HOUSING REMOVAL AND INSTALLATION
For replacement of water pump or front crankshaft seal or both, remove and replace at this time. Service and Repair
INSPECTION
1. TIMING BELT
(1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt.
(2) Check the condition of back side of belt; if any crack is found, replace belt.
NOTE:
a. Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens.
b. Do not bend the belt sharply. The bending radius must be greater than 60 mm (2.36 in).
2. BELT TENSION ADJUSTER
(1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace faulty parts.
NOTE: Slight traces of oil at rod oil seal does not indicate a problem.
(2) While holding tensioner with both hands, push the rod section against floor or wall with a force of 147 to 490 N (15 to 50 kg, 33 to 110 lb) to ensure that the rod section does not move. If it moves, replace tension adjuster with a new one.
3. Measure the extension of rod beyond the body. if it is not within specifications, replace with a new one.
Rod extension H: 15.4 - 16.4 mm (0.606 - 0.646 in)
3. BELT TENSIONER
(1) Check mating surfaces of timing belt and contact point of tension adjuster rod for abnormal wear or scratches. Replace belt tensioner if faulty.
(2) Check spacer and tensioner bushing for wear.
4. BELT IDLER
(1) Check idler for smooth rotation. Replace if noise or excessive play is noted.
INSTALLATION
1. SPROCKET
1. Install right-hand belt cover No.2. To lock camshaft, use CAMSHAFT SPROCKET WRENCH
2. Install left-hand belt cover No.2.
3. Install tensioner bracket.
4. Install crankshaft sprocket.
5. Install right-hand camshaft sprocket. during installation.
6. Install left-hand camshaft sprocket.
NOTE: Do not confuse left-and right-hand camshaft sprockets. The left-hand camshaft sprocket is identified by a projection used to monitor cam angle sensor.
2. BELT TENSIONER AND IDLER
1. Installation of belt tensioner adjuster.
(1) Insert stopper pin 1.5 mm (0.059 in) dia. into place while pushing tension adjuster rod into body using a press.
a. Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 lb).
b. Do not release press pressure until stopper pin is completely inserted.
c. Push tension adjuster rod vertically.
(2) Temporarily tighten bolts while tension adjuster is pushed all the way to the right.
2. Install belt tensioner.
3. Install belt idler
3. TIMING BELT
1. Installation of timing belt.
(1) Using SPROCKET WRENCH, turn sprockets so that their alignment marks come to top positions.
(2) While aligning alignment mark on timing belt with marks on sprockets, position timing belt properly.
NOTE: Ensure belt's rotating direction is correct.
Timing Mark Alignment:
2. Install bell idler No.2.
3. Install belt idler.
Tensioner Adjustment:
4. Loosen tension adjuster attaching bolts and move adjuster all the way to the left. Tighten the bolts.
5. After ensuring that the marks on timing belt and sprockets are aligned, remove stopper from tension adjuster.
Note: After properly installing timing belt, remove rocker cover and ensure that the valve lash adjuster contains no air.
4. CRANKSHAFT PULLEY AND BELT COVER
1. Install front belt cover.
2. Install right-hand belt cover and plate CP-belt cover (TURBO).
3. Install left-hand belt cover.
4. Install crankshaft pulley.
5. Install pulley bolt.
6. Install V-belt.
Tightening torque: N.m (kg-m, ft-lb)
T1: 5 (0.5, 3.6).
T2: 93 - 103 (9.5 - 10.5, 69 - 76).