Timing Belt: Service and Repair

TIMING BELT






DISASSEMBLY

1. Loosen the coolant pump pulley bolts.






2. Loosen the alternator bolt.

3. Remove the coolant pump pulley and belt.

4. Remove the crankshaft pulley.






5. Remove the timing belt cover.






6. 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.






7. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it.






8. Remove the timing belt.






9. Remove the camshaft sprocket.

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

11. Remove the timing belt tensioner.

INSPECTION

TIMING BELT

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

2. When the engine is overhauled or belt tension adjusted, carefully check the belt. If any of the following flaws are evident, replace the belt.






NOTE
A normal belt should have precisely cut sides as if cut by a sharp knife.

9. Side of belt cracked

SPROCKETS AND TENSIONER

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

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






REASSEMBLY

1. Install the flange and crankshaft sprocket as shown.
Pay close attention to their mounting directions.






Tightening torque
Crankshaft sprocket bolt :
140 - 150Nm (1400 - 1500kg.cm, 103 - 111lb.ft)

2. Install the camshaft sprocket and tighten the bolt to the specified torque.

Tightening torque
Camshaft sprocket bolt :
80 - 100 Nm (800 - 1000 kg.cm, 59 - 74 lb.ft)

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






NOTE
When installing camshaft sprocket. Make sure that camshaft sprocket knock pin fits small hole in pulley as shown.

4. Tentatively fasten the timing belt tensioner where its pulley is nearest the water pump body.






5. Hang the tensioner spring on the tensioner bracket and insert the other side into the front case using a screw driver.






6. Install the timing belt tightly in the sequence shown.
1-Crankshaft sprocket, 2-Camshaft sprocket, 3-Timing belt tensioner.






7. Install timing belt so as not to give slack to tension side.

NOTE
Then make sure that timing marks are at correct position respectively with tension side in strained state by applying force to camshaft sprocket in reversing direction.

8. Loosen the tensioner mounting bolt in the order as shown to give the timing belt spring tension.






9. Rotate crankshaft in regular direction (clockwise view from front) through angle equivalent to two teeth (15�) of camshaft sprocket.

10. Add force to tensioner in direction of regular rotation to bring belt teeth in perfect contact with sprocket teeth without a gap.

11. After making sure of this state. Fix tensioner so that only the tensioner spring is movable.

12. Rotate the crankshaft pulley two or four turns counter clockwise so that the timing belt positions itself on the sprockets.

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. 49N (11 lb)], the timing belt is half of the tensioner mounting bolt head radius away from the bolt head center.






14. Install the timing belt cover.

15. Install the crankshaft pulley.

16. Install the A/C compressor belt and adjust the belt tension.

17. Install the coolant pump pulley.

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