Timing Belt: Service and Repair

REMOVAL








1. Take down alternator and water pump pulley.








2. Remove crankshaft pulley by removing 4 pulley bolts, with special tool (A) hitched to flywheel so that crankshaft will not turn. The crank timing belt pulley bolt at the center needs not to be loosened.





3. Remove outside cover on timing belt.





4. Loosen tensioner bolt and stud, and remove belt from crank timing belt pulley and cam shaft pulley after pushing up tensioner plate fully by finger as shown in Figure.

5. Remove timing belt tensioner, tensioner plate, and tensioner spring.





6. Remove camshaft timing belt pulley by locking camshaft (insert general rod into the camshaft hole) as shown below.





7. Using flywheel holder (A) (Special tool), remove crankshaft timing belt pulley bolt, pulley and timing belt guide with crankshaft locked.

8. Remove crankshaft timing belt pulley key.

INSTALLATION

Timing Belt Pulleys, Timing Belt and Tensioner.





1. Crankshaft timing belt pulley.
Install timing belt guide, key, and crankshaft timing belt pulley. Refer to figure for proper installation of these parts. Install timing belt guide in such a way that its concave side faces oil pump. With crankshaft locked, tighten crankshaft timing belt pulley bolt to specified torque.

Tightening Torque:
105-115 N.m (10.5-11.5 kg-m, 76.0-83.0 lb-ft)








2. Camshaft timing belt pulley.
Fit pulley pin on camshaft into slot on camshaft pulley. With camshaft locked, tighten the pulley bolt to the specified torque.

Tightening Torque:
56-64 N.m (5.6-6.4 kg-m, 41.0-46.0 lb-ft)

3. Tensioner and timing belt





a) Insert lug of tensioner plate into hole of tensioner.





b) Tensioner, tensioner plate, spring and spring damper:
Do not tighten the tensioner bolt and stud by wrench yet. Hand tighten only at this time. Check to ensure that the plate movement in arrow direction as shown in below figure causes the same directional movement of the tensioner. If no associated movement between plate and tensioner occurs, remove tensioner and plate again and reinsert the plate lug into tensioner hole.





c) Before installing timing belt to camshaft timing belt pulley and crankshaft timing belt pulley, loosen all valve adjusting screws of intake and exhaust rocker arms fully, or check to ensure they are loose. This is to permit free rotation of camshaft for the reason is; when installing timing belt to both pulleys, belt should be correctly tensed by tensioner spring force. If camshaft does not rotate freely, belt will not be correctly tensed by tensioner.





d) After loosening all valve adjusting screws all the way, turn camshaft pulley clockwise and align timing mark on camshaft pulley with "V" mark on the belt inside cover as shown in figure below.





e) Turn crankshaft clockwise, fitting 17 mm wrench to crank timing belt pulley bolt, and align punch mark on timing belt pulley with the arrow mark on oil pump as shown in below figure.





f) With two sets of marks aligned, install timing belt on two pulleys in such a way that the drive side of belt is free of any slack, and with tensioner plate pushed up by finger.

NOTE:
^ When installing timing belt, match arrow mark on timing belt with rotating direction of crankshaft.
^ In this state, No.4 piston is at top dead center of compression stroke.





g) To take up slack of timing belt, turn crankshaft two rotations clockwise after installing it. After making sure that belt is free from slack, tighten tensioner stud first and then tensioner bolt to each specified torque. Then confirm again that two sets of marks are aligned respectively.

Tightening Torque:
Tensioner stud 9-12 N.m (0.9-1.2 kg-m, 7.0-8.5 ft-lb)
Tensioner bolt 24-30 N.m (2.4-3.0 kg-m, 17.5-21.5 ft-lb)





4. Install outside cover on timing belt.





5. Install crankshaft pulley

6. Install water pump pulley and drive belt.