Timing Belt: Service and Repair

A: REMOVAL
1. TIMING BELT





1. Remove timing belt guide. (MT vehicles only)
2. 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 shown in procedures below.





1 of 2





2 of 2

1. Turn crankshaft using ST. Align mark (a) of sprocket to cylinder block notch (b) and ensure that right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) and/or left side cam sprocket mark (e) and belt cover notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET





2. Using white paint, put alignment and/or arrow marks on timing belts in relation to the crank sprocket and cam sprockets.





Specified data:
Z1: 44 tooth length
Z2: 40.5 tooth

3. Remove belt idler (No. 2).





4. Remove halt idler No. 2.





5. Remove timing belt.

2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY





1. Remove belt idler (No. 1).





2. Remove automatic belt tension adjuster assembly.

B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT 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 N (30 kgf, 66 lbs.).
^ Press-in the push adjuster rod gradually take more than three minutes.
^ Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbs.).
^ Press the adjuster rod as far as the end surface-face 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 N (30 kgf, 66 lb.) 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.
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)





3. Install belt idler (No. 1).
Tightening torque: 39 Nm 4.0 kgf-m, 28.9 ft. lbs.)

2. TIMING BELT
1. Installation of timing belt





1. Turn camshaft sprocket No. 2 using ST1, and turn camshaft sprocket No. 1 using ST2 so that their alignment marks come to top positions.
ST1 499207100 CAMSHAFT SPROCKET WRENCH
ST2 499207400 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.
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)





3. Install belt idler (No. 2).
Tightening torque: 39 Nm (4.0 kgf-m. 28.9 ft. lbs.)
4. After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper pin from belt tensioner adjuster.





CAUTION: After properly installing timing belt, remove rocker cover and ensure that the valve lash adjuster contains no air.

5. Install timing belt guide. (MT vehicles only)





1. Temporarily tighten remaining bolts.





2. Check and adjust clearance between timing belt and timing belt guide by using thickness gauge.
Clearance: 1.0 ±0.5 mm (0.039 ±0.020 inch)





3. Tighten remaining bolts.
Tightening torque: 9.8 Nm (1.0 kgf-m, 7.2 ft. lbs.)