Timing Belt: Service and Repair

TIMING BELT

REMOVAL

1. Loosen the water pump pulley bolt.

2. Loosen the alternator belt.

3. Remove the water pump pulley and belt.

4. Remove the crankshaft pulley.

5. Remove the timing belt cover.





6. Move the timing belt tensioner fully toward the water pump, and temporarily secure it.

7. Remove the timing belt from the camshaft sprocket.

8. Remove the camshaft sprocket.

9. Remove the timing belt.





NOTE: If the timing belt is reused make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before.

10. Remove the crankshaft sprocket bolts. Remove the crankshaft sprocket and flange.

11. Remove the timing belt tensioner.



INSPECTION

Sprockets and Tensioner

1. Check the camshaft sprocket, crankshaft sprocket and tensioner for abnormal wear, cracks, or damage. Replace as necessary.





2. Inspect the tensioner for easy and smooth pulley rotation and check for play or noise. Replace as necessary.

Timing Belt

1. Check the belt for oil or dust deposits. Replace if necessary. Small deposits should be wiped away with a dry cloth. Do not clean with solvent.









2. When the engine is overhauled or belt tension adjusted, check the belt in detail. If flaws are evident, as shown in images, replace the belt with a new one.

INSTALLATION





1. Install the flange and crankshaft sprocket as shown in image. Pay close attention to their mounting directions. Tighten crankshaft sprocket bolt to the specified torque. 190 - 200 Nm (1900 - 2000 kg) (140 - 147.5 ft lb).

2. Install the camshaft sprocket and tighten the bolt to the specified torque. 13 - 14 Nm (130 - 140 kg) (9.6 - 10.3 ft lb).





3. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston placed at top dead center on its compression stroke.





4. To install the timing belt tensioner, first mount the tensioner, spring, and spacer. Temporarily tighten the bolts. Next, temporarily tighten the tensioner long hole side washer and bolts. Install the bottom end of the spring against the front case as shown in the image.





5. Secure the tensioner, positioned towards the water pump.

6. Install the timing belt on the crankshaft sprocket.

7. Install the timing belt on the camshaft sprocket, make sure that the tension side is tight. Then, check to ensure that when the tension side is tightened by turning the camshaft sprocket in a reverse direction, all timing marks are in line.





8. Loosen the tensioner mounting bolts "1" and "2" in that order as shown in image. This will apply spring tension to the timing belt only.

NOTE: Check the belt to ensure that it is not out of position.

9. Tighten the tensioner mounting bolts "1" and "2" in that order. If bolt "1" is tightened first, the tensioner will move with the belt in the direction that the belt is tightened.

10. Give the crankshaft one turn in operating direction (clockwise) and realign crankshaft sprocket timing mark with the top dead center position.

CAUTION:
- Do not turn the crankshaft in a counterclockwise direction. The crankshaft should turn smoothly.

11. Loosen the tensioner attaching bolts "1" and "2" in that order.

12. Tighten the tensioner attaching bolts "2" and "1" in that order to the specified torque. 20 - 27 Nm (200 - 270 kg) (14 - 20 ft lb).





13. Recheck the belt tension. Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49 N (11 lb)], the timing belt cog end is approx. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center.





14. Install the timing belt cover. Tighten the timing belt cover bolts to the specified torque. 10 - 12 Nm (100 - 120 kg) (7.2 - 8.7 ft lb).

15. Install the crankshaft pulley.

NOTE: Make sure the crankshaft sprocket pin fits the small hole in the pulley. Tighten the crankshaft pulley bolts to the specified torque. 10 - 12 Nm (100 - 120 kg) (7.2 - 8.7 ft lb).

16. Install the fan belt and adjust the belt tension.

17. Install the water pump pulley.

18. Install V-belt and adjust the belt tension.