Timing Belt: Service and Repair

REPLACEMENT
1. DRAIN ENGINE COOLANT
2. SEPARATE BATTERY NEGATIVE TERMINAL
3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY
a. Remove the 2 nuts and throttle body cover sub-assembly.
4. REMOVE AIR CLEANER HOSE ASSEMBLY
5. REMOVE RADIATOR SUPPORT SEAL UPPER
a. Remove the 11 clips and radiator support seal upper.
6. REMOVE FAN AND GENERATOR V BELT





7. REMOVE FAN W/ FLUID COUPLING
a. Unfasten each clip and the 2 hose clamps, and then separate the 2 oil cooler hoses from the fan shroud.
b. Remove the 3 bolts and separate the fan shroud from the radiator.
c. Remove the 4 nuts and separate the fan w/ fluid coupling from the engine.
d. Remove the fan shroud and fan w/ fluid coupling together from the vehicle.
e. Remove the fan pulley.





8. SEPARATE VANE PUMP ASSEMBLY
a. Disconnect the vacuum hose.
b. Remove the nut, 2 bolts and vane pump assembly.

HINT: Hang up the hoses instead of detaching.

9. REMOVE GENERATOR ASSEMBLY





10. SEPARATE COMPRESSOR
a. Disconnect the compressor connector.
b. Remove the nut, 3 bolts, compressor stay and compressor.

HINT: Hang up the hoses instead of detaching.





11. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the pulley bolt, cover plate and idler pulley.
12. REMOVE OIL COOLER PIPE
a. Disconnect the 3 hoses.
b. Remove the bolt, nut and oil cooler pipe.





13. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Remove the grommet and separate the cam position sensor connector from the timing belt cover sub-assembly No.3 LH.
b. Remove the 4 bolts and timing belt cover sub-assembly No.3 LH.
14. REMOVE TIMING CHAIN OR BELT COVER NO.2
a. Remove the nut, 3 bolts and timing belt cover No.2.
15. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and timing belt cover sub-assembly No.2.
16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and V-ribbed belt tensioner.
17. REMOVE FAN BRACKET SUB-ASSEMBLY
a. Remove the 2 nuts, 2 bolts and fan bracket sub-assembly.
18. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY





a. Using SST, remove the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021





b. Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021),





19. REMOVE TIMING BELT NO.1 COVER
a. Remove the 4 bolts and timing belt cover.





20. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
21. REMOVE TIMING BELT





a. If reusing the timing belt, check the installation marks on the timing belt.
1 Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part.





b. Set the No.1 cylinder to approx. 50° BTDC/compression.
1 Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.





2 Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 complete revolution (360°).





3 Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 50°.

NOTICE: If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.





c. Alternately loosen the 2 bolts, then remove the bolts, the chain tensioner and dust boot.





d. Using a SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by turning the camshaft timing pulley (RH bank) counterclockwise slightly.
SST 09960-10010 (09962-01000, 09963-00350)
e. Disconnect the timing belt from the timing belt idler No.1 and remove the timing belt.
22. INSTALL TIMING BELT
a. Check the timing belt idlers No.1 and No.2.
1 Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler.
2 Check that the idler turns smoothly.
If necessary, replace the idler.





b. Check the water pump.
1 Visually check the air hole and water hole for coolant leakage.
If leakage is found, replace the water pump and timing belt.
2 Turn the pulley, and check that the water pump bearing moves smoothly.
If necessary, replace the water pump.
c. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, idler No.1 and idler No.2, and keep them clean.

NOTICE: Only wipe the pulleys; do not use any cleaning agent.





d. Set the No.1 cylinder to the TDC/compression.
1 Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.





HINT: By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:
1/2 teeth turn for the left bank camshaft timing pulley
1 tooth turn for the right bank camshaft timing pulley





2 Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.





e. Install the timing belt.
1 Remove any oil or water on the each pulley, and keep them clean.

NOTICE: Only wipe the pulleys; do not use any cleansing agent.

2 Face the front mark (arrow) on the timing belt forward.
3 Put the timing belt on the crankshaft timing pulley.
^ Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
4 Put the timing belt on the idler No.2.
5 Put the timing belt on the camshaft timing pulley (LH bank).
^ Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
6 Put the timing belt on the water pump pulley.
7 Put the timing belt on the camshaft timing pulley (RH bank).
^ Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
8 Put the timing belt on the idler No.1.





f. Set the belt tensioner.
1 Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 ft. lbs.) of pressure.
2 Align the holes of the push rod and housing, and pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
3 Release the press.
4 Install the dust boot to the belt tensioner.





g. Install the belt tensioner.
1 Temporarily install the belt tensioner with the 2 bolts.
2 Alternately tighten the 2 bolts.
Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.)
3 Using pliers, remove the 1.27 mm hexagon wrench from the chain tensioner.





h. Check the valve timing.
1 Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.

NOTICE: Always turn the crankshaft pulley clockwise.





2 Check that each pulley is aligned with each timing mark as shown in the illustration.
If the timing marks are not aligned, remove the timing belt and reinstall it.
3 Remove the crankshaft damper bolt.





23. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate as shown in the illustration.

NOTICE: Take care not to install it in a wrong direction.





24. INSTALL TIMING BELT NO.1 COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
25. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY





a. Align the pulley set key with the key groove of the crankshaft damper.
b. Using SST and a hammer, tap in the crankshaft damper.
SST 09223-46011





c. Using SST, install the damper bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)





26. INSTALL FAN BRACKET SUB-ASSEMBLY
a. Install the idler pulley with the 2 bolts and 2 nuts.
Torque:
16 Nm (160 kgf-cm, 12 ft. lbs.) for 12 mm head
32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head

HINT: Each bolt length is as follows:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)





27. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (160 kgf-cm, 11 ft. lbs.)

HINT: Use a bolt 106 mm (4.17 inch) in length.





28. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Install the timing belt cover and fit the claws and pins into each part.
b. Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)

HINT: Use bolts 106 mm (4.17 inch) in length.

29. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Install the timing belt cover sub-assembly with the 4 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
b. Install the camshaft position sensor connector and grommet to the timing belt cover.
30. INSTALL TIMING CHAIN OR BELT COVER NO.2
a. Install the timing chain or belt cover with the nut and 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
31. INSTALL OIL COOLER PIPE
a. Install the oil cooler pipe with the bolt and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
b. Connect the 3 hoses.





32. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
33. INSTALL COMPRESSOR
a. Install the compressor with the stay, nut and 3 bolts.
Torque:
Bolt: 47 Nm (475 kgf-cm, 34 ft. lbs.)
Nut: 25 Nm (255 kgf-cm, 18 ft. lbs.)
34. INSTALL GENERATOR ASSEMBLY
35. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump assembly with the nut and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
36. INSTALL FAN W/ FLUID COUPLING
a. Install the fan pulley to the engine.
b. Put the fan w/ fluid coupling and fan shroud together into the engine room.
c. Install the fan shroud with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
d. Install the fan w/ fluid coupling with the 4 nuts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
37. INSTALL FAN AND GENERATOR V BELT
38. INSTALL RADIATOR SUPPORT SEAL UPPER
39. INSTALL AIR CLEANER HOSE ASSEMBLY
40. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY
a. Install the throttle body cover sub-assembly with the 2 nuts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
41. ADD ENGINE COOLANT
42. CHECK FOR ENGINE COOLANT LEAKS