Timing Belt: Service and Repair
CAUTION: INTERFERENCE ENGINEWhen installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.
The contents of this article reflects service manual update
18-137-09 dated 02/23/09.
Timing Belt Assembly
REMOVAL
TIMING BELT
1. Remove the V-belt.
2. Remove the crankshaft pulley.
3. Remove the belt cover.
4. Remove the timing belt guide. (MT vehicles)
5. If the alignment mark (a) and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below.
1. Turn the crankshaft using ST. Align the mark (a) of sprocket to cylinder block notch (b) and ensure the 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 the timing belts in relation to crank sprocket and cam sprockets.
Specified data:
Z1: 46.8 tooth length
Z2: 43.7 tooth length
6. Remove the belt idler (No. 2).
7. Remove the belt idler No. 2.
8. Remove the timing belt.
BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY
1. Remove the belt idler (No. 1).
2. Remove the automatic belt tension adjuster assembly.
INSTALLATION
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 the adjuster rod vertically.
^ Press-in the push adjuster rod gradually taking more than 3 minutes.
^ Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb).
^ Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
^ Do not release the 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 165 N (16.8 kgf, 37.1 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 the automatic belt tension adjuster assembly.
Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft. lbs.)
3. Install the belt idler (No. 1).
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
TIMING BELT
1. Preparation for the installation of automatic belt tension adjuster assembly.
2. Installation of timing belt
1. Turn the camshaft sprocket No. 2 using ST1, and then turn the camshaft sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions.
ST1 18231 AA010 CAMSHAFT SPROCKET WRENCH
NOTE: Also the CAMSHAFT SPROCKET WRENCH (499207100 can be used.
ST2 499207400 CAMSHAFT SPROCKET WRENCH
2. While aligning alignment mark on the timing belt (B) with marks on sprockets (A), position the timing belt properly.
3. Install the belt idler No. 2.
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
4. Install the belt idler (No. 2).
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
5. After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove the stopper pin from belt tension adjuster.
6. Install the timing belt guide. (MT vehicles)
1. Temporarily tighten the remaining bolts.
2. Check and adjust the 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 the remaining bolts.
Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft. lbs.)
7. Install the belt cover.
8. Install the crankshaft pulley.
9. Install the V-belt.
INSPECTION
TIMING BELT
1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt.
2. Check the condition of back side of belt; if any crack is found, replace the 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.
2. Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) 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 N (30 kgf, 66 lb), 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 N (30 kgf, 66 lb) 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 the adjuster rod vertically.
^ Press-in the push adjuster rod gradually taking more than 3 minutes.
^ Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb).
^ 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 5.7+0.5 mm (0.224+0.020 inch)
BELT TENSION PULLEY
1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly if faulty.
2. Check the tension pulley for smooth rotation. Replace if noise or excessive play is noted.
3. Check the tension pulley for grease leakage.
BELT IDLER
1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted.
2. Check the belt outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check the belt idler for grease leakage.