Non-Equipped New Automatic Belt Tension Adjuster

REMOVAL





Crankshaft Pulley And Belt Cover





1) Remove V-belt and A/C belt tensioner.
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 (2) 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 (2) on crankshaft sprocket, and left and right camshaft sprockets with notches (1) 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) Loosen belt tensioner adjuster mounting bolts.
3) Remove belt idler No. 2.
4) Remove belt idler No. 2.
5) Remove timing belt.





Belt Tensioner And Idler
1) Remove belt idler (No. 1).
2) Remove belt tensioner assembly.
3) Remove belt tensioner adjuster.





Sprocket





1) Remove camshaft sprocket No. 2.
2) Remove camshaft sprocket No. 1. To lock camshaft use ST.
ST# 499207100 CAMSHAFT SPROCKET WRENCH
3) Remove crankshaft sprocket.
4) Remove belt cover No. 2 (Left-Hand).
5) Remove belt cover No. 2 (Right-Hand).

CAUTION: Do not damage or lose the seal rubber when removing belt covers.

6) 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

Belt Tensioner Adjuster
1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace belt tensioner adjuster.

CAUTION: Slight traces of oil at rod' oil seal does not indicate a problem.

2) While holding bell tensioner adjuster with both hands, push the rod section against floor or wall ensuring the rod section will react as follows:
(1) When applying a force of 147 Nm (15 kg, 33 lbs.), the rod section should not sink.
(2) When applying a force of 147 to 490 Nm (15 to 50 kg, 33 to 110 lbs.), the rod section should maintain a projectionally acting force and should not sink within 8.5 seconds.





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 inch)

Belt Tensioner
1) Check mating surfaces of timing belt and contact point of belt tensioner adjuster rod for abnormal wear or scratches. Replace belt tensioner if faulty.
2) Check spacer and tensioner bushing for wear.
3) Check belt tensioner for smooth rotation. Replace if noise or excessive play is noted.
4) Check belt tensioner 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 belt idler for abnormal wear and scratches.
3) Check belt 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 belt cover No. 2 (Right-Hand),
2) Install tensioner bracket.
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) Installation of belt tensioner adjuster
(1) Insert stopper pin 1.5 mm (0.059 inch) diameter into place while pushing adjuster rod into body using a press.

CAUTION:
^ Do not allow press pressure to exceed 9,807 Nm (1,000 kg, 2,205 lbs.).
^ Do not release press pressure until stopper pin is completely inserted.
^ Push belt tensioner adjuster rod vertically.
^ Press-in the push adjuster rod gradually taking three minutes or more.

(2) Install belt tensioner adjuster to tensioner bracket.
2) Install belt tensioner assembly.
3) Install belt idler (No. 1).





4) Temporarily tighten bolts while belt tensioner adjuster is pushed all the way to the right.






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 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).

Tensioner Adjustment:

4) Loosen belt tensioner 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 camshaft sprockets are aligned, remove stopper pin from belt tensioner 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.