Timing Belt: Service and Repair

TIMING BELT

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE FR WIPER ARM LH
3. REMOVE FR WIPER ARM RH
4. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
5. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
6. REMOVE COWL PANEL SUB-ASSEMBLY
7. REMOVE ENGINE UNDER COVER NO. 1
8. REMOVE FRONT FENDER APRON SEAL RH
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1)
10. REMOVE VANE PUMP V BELT
11. REMOVE ENGINE MOVING CONTROL ROD
12. REMOVE ENGINE MOUNTING STAY NO. 2 RH
13. REMOVE GENERATOR BRACKET NO. 2

14. REMOVE CRANKSHAFT PULLEY
a. Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021

b. Using SST and the pulley bolt, remove the pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

NOTICE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 100.

15. REMOVE TIMING BELT NO. 1 COVER

16. REMOVE TIMING BELT NO. 2 COVER
a. Disconnect the engine wire protector clamps from the timing belt No. 3 cover.
b. Remove the 5 bolts and timing belt cover.
17. REMOVE ENGINE MOUNTING BRACKET RH
18. REMOVE TIMING BELT GUIDE NO. 2

19. REMOVE TIMING BELT
a. Set the No. 1 cylinder to TDC/compression.
(1) Temporarily install the crankshaft pulley bolt with the washer to the crankshaft.
(2) Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley and oil pump body.

(3) Check that the timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360°).
(4) Remove the crankshaft pulley bolt.

b. If planning to reuse the timing belt, check that there are 4 installation marks on the timing belt, as shown in the illustration.
(1) If the installation marks have disappeared, put new installation marks on the timing belt before removing.

c. Set the No. 1 cylinder to approximately 60° BTDC/compression.
(1) Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: With the timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and then the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and be damaged.

d. Remove the timing belt tensioner.

NOTICE: Do not reinstall the tensioner with its plunger extended.

e. Remove the timing belt in this order.

INSTALLATION
1. INSTALL TIMING BELT
a. Remove any oil or water on the pulleys, and keep them clean.

NOTICE:
^ If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
^ Do not use cleaning agents on the pulleys when cleaning them.

b. Inspect the idler pulleys.
(1) Check that the idler pulleys turn smoothly.
(2) Visually check the sealed portion of the idler pulleys for oil leakage. If there is any doubt about the idler pulleys condition, replace the idler pulleys.
c. Inspect the water pump.
(1) Turn the pulley, and check that the water pump bearing moves smoothly without any noise.
(2) Visually check the drain hole for coolant leakage. If there is any doubt about the water pump condition, replace the water pump.
d. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.

e. Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: To prevent the piston head and the valve head from colliding, set the crankshaft pulley at approximately 60° BTDC/compression position.

f. Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No. 3 timing belt cover.
SST 09960-10010 (09962-01000, 09963-01000)

g. Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.

h. Face the front mark on the timing belt forward.
i. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
j. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

k. Install the timing belt in this order.

2. INSTALL TIMING BELT TENSIONER ASSEMBLY
a. Set the timing belt tensioner uprightly on the press.
b. Slowly press in the push rod.

NOTICE: Do not apply pressure of more than 9.8 kN (1,000 kgf, 2,205 ft. lbs.) to the rod.

c. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
d. Release the push rod.
e. Temporarily install the tensioner with the 2 bolts.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

NOTICE: Install the tensioner's bolts uniformly and evenly. Installing the tensioner at an angle may cause it to malfunction.

f. Remove the 1.5 mm hexagon wrench from the tensioner.

g. Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body.

NOTICE: Always turn the crankshaft clockwise.

h. Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover, as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
i. Remove the crankshaft pulley bolt.

3. INSTALL TIMING BELT GUIDE NO. 2
a. Install the timing belt guide, facing the cup side toward the engine front.
4. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
5. INSTALL TIMING BELT NO. 2 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.

HINT: If it is judged that water is entering at the visual check, replace the timing belt cover.

b. Install the timing belt cover.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
6. INSTALL TIMING BELT NO. 1 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.

HINT: If there is a trace that water is entering at the visual check, replace the timing belt cover.

b. Install the timing belt cover.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
c. Install the engine wire protector cover to the timing belt No. 3 cover.

7. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley
b. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 Nm (2,243 kgf-cm, 162 ft. lbs.)
8. INSTALL GENERATOR BRACKET NO. 2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
9. INSTALL ENGINE MOUNTING STAY NO. 2 RH
10. INSTALL ENGINE MOVING CONTROL ROD
11. INSTALL VANE PUMP V BELT
12. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
13. INSTALL DRIVE BELT TENSION
14. INSTALL FRONT FENDER APRON SEAL RH
15. INSTALL ENGINE UNDER COVER NO. 1
16. INSTALL COWL PANEL SUB-ASSEMBLY
17. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
18. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
19. INSTALL FR WIPER ARM LH
20. INSTALL FR WIPER ARM RH
21. INSTALL FRONT WHEEL RH