Equipped New Automatic Belt Tension Adjuster
REMOVAL
Crankshaft Pulley And Belt Cover
1) Remove V-belt.
2) Remove crankshaft pulley bolt. To lock crankshaft use Special Tool(ST).
(ST) 499977000 CRANKSHAFT PULLEY WRENCH
3) Remove crankshaft pulley.
4) Remove belt cover (Left-Hand).
5) Remove belt cover (Right-Hand).
6) Remove front belt cover,
Timing Belt
1) If alignment mark (A) and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows:
1) Turn crankshaft, and align alignment marks (A) on crankshaft sprocket, and left and right camshaft sprockets with notches of belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets.
Z1: 44 tooth length Z2: 40.5 tooth length
2) Remove belt idler (No. 2).
3) Remove belt idler No. 2.
4) Remove timing belt.
Automatic Belt Tension Adjuster Assembly And Belt Idler
1) Remove belt idler (No. 1).
2) Remove automatic belt tension adjuster assembly.
Sprocket
1) Remove camshaft sprocket No. 1 and No. 2. To lock camshaft use ST.
ST 499207100 CAMSHAFT SPROCKET WRENCH
2) Remove crankshaft sprocket.
3) Remove belt cover No. 2 (Left-Hand).
4) Remove belt cover No. 2 (Right-Hand).
CAUTION: Do not damage or lose the seal rubber when removing belt covers.
5) Remove tensioner bracket.
INSPECTION
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,
CAUTION:
^ Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens.
^ Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 inch) or more
Automatic Belt Tension Adjuster
1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace faulty parts.
CAUTION: Slight traces of oil at rod's oil seal does not indicate a problem.
2) Check that the adjuster rod does not move when a pressure of 294 Nm (30 kg, 66 lbs.) is applied to it. This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely when applying 294 Nm (30 kg, 66 lbs.), check it using the following procedures:
1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times.
2) With the adjuster rod moved all the way up, apply a pressure of 294 Nm (30 kg, 66 lbs.) to it. Check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one.
CAUTION:
^ Always use a vertical type pressing tool to move the adjuster rod down.
^ Do not use a lateral type vise.
^ Push adjuster rod vertically.
^ Press-in the push adjuster rod gradually taking more than three minutes.
^ Do not allow press pressure to exceed 9,807 Nm. (1,000 kg, 2,205 lbs.).
^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one.
Rod extension: H 6.0 ± 0.5 mm (0.236 ± 0.020 inch)
Belt Tension Pulley
1) Check mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace belt tension pulley if faulty.
2) Check belt tension pulley for smooth rotation. Replace if noise or excessive play is noted.
3) Check belt tension pulley for grease leakage.
Belt Idler
1) Check belt idler for smooth rotation. Replace if noise or excessive play is noted.
2) Check outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check bell idler for grease leakage.
Camshaft And Crankshaft Sprocket
1) Check sprocket teeth for abnormal wear and scratches.
2) Make sure there is no free play between sprocket and key.
3) Check crankshaft sprocket notch for sensor for damage and contamination of foreign matter.
INSTALLATION
Camshaft And Crankshaft Sprocket
1) Install tensioner bracket.
2) Install belt cover No. 2 (Right-Hand).
3) Install belt cover No. 2 (Left-Hand).
4) Install crankshaft sprocket.
5) Install camshaft sprocket No. 1 and camshaft sprocket No. 2. To lock camshaft use ST.
ST 499207100 CAMSHAFT SPROCKET WRENCH
CAUTION: Do not confuse left and right side camshaft sprockets during installation. The camshaft sprocket No. 2 is identified by a projection used to monitor camshaft position sensor.
Belt Tensioner And Idler
1) Preparation for installation of automatic belt tension adjuster assembly;
CAUTION:
^ Always use a vertical type pressing tool to move the adjuster rod down.
^ Do not use a lateral type vise.
^ Push adjuster rod vertically.
^ Be sure to slowly move the adjuster rod down applying a pressure of 294 Nm (30 kg, 66 lbs.).
^ Press-in the push adjuster rod gradually taking more than three minutes.
^ Do not allow press pressure to exceed 9,807 Nm (1,000 kg, 2,205 lbs.).
^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
^ Do not release press pressure until stopper pin is completely inserted.
1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool.
2) Slowly move the adjuster rod down with a pressure of 294 Nm (30 kg, 66 lbs.) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
3) With a 2 mm (0.08 inch) dia. stopper pin or a 2 mm (0.08 inch) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
2) Install automatic belt tension adjuster assembly.
3) Install bell idler (No. 1).
Timing Belt
1) Installation of timing belt.
1) Using ST, turn left and right camshaft sprockets so that their alignment marks come to top positions.
ST 499207100 CAMSHAFT SPROCKET WRENCH
2) While aligning alignment mark (A) on timing belt with marks on sprockets, position timing belt properly.
CAUTION: Ensure belt's rotating direction is correct.
2) Install belt idler No. 2.
3) Install belt idler (No. 2).
4) After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper pin from automatic belt tension adjuster.
Crankshaft Pulley And Belt Cover
1) Install front belt cover.
2) Install belt cover (Right-Hand).
3) Install belt cover (Left-Hand).
4) Install crankshaft pulley.
5) Install pulley bolt. To lock crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY WRENCH
6) Install V-belt.