Timing Belt: Service and Repair

TIMING BELT REMOVAL




1. Disconnect the battery ground cable.




2. Remove the power steering pump drive belt (for vehicles with air conditioners, remove the power steering pump and compressor drive belt).
Loosen the two power steering pump adjust plate bolts.

3. Remove the alternator drive belt.
The belt can be easily removed from the crank pulley side.




4. Disconnect the clip securing the high pressure air conditioning line to the strut tower.




5. Remove the timing belt upper cover.




6. Support the engine by using an engine hoist.
7. Remove the passenger side engine mount from the engine.
8. Disconnect the torque rod at the firewall.




9. Remove the passenger side engine mounting bracket from the engine.




10. Use special tool No. J-37988 and remove the crank pulley bolt.
11. Raise the passenger side of the engine.

Note: Ensure the front wheel remains on the ground while lifting the engine. Raising the engine too high will lift the front wheel off the ground and may cause damage to the drive shaft universal joint.

12. Remove the timing belt lower cover.
13. Remove the crank pulley and extract up through the engine compartment.
14. Refit the crank pulley bolt.




15. Align the crank pulley timing gear to TDC.

16. Loosen the tension pulley bolt 1/2 turn counter clockwise.

Note: If the pulley bolt is loosened more than 1/2 a turn the pulley will swing too far out of adjustment and will be difficult to readjust.

17. Remove the timing belt.

TIMING BELT INSTALLATION
1. Align the camshaft pulley timing marks.




2. Lock the camshaft pulley in position by inserting a 6 mm bolt through the camshaft pulleys and into the cylinder head.




3. Align the crank pulley timing gear to TDC.




4. Install the timing belt.

NOTES:
A) To ensure the belt is installed correctly the lettering must be able to be read while viewing it from the passenger side fender.
B) The belt must be installed in the following.
1) Crankshaft Timing gear
2) Water pump
3) Idle pulley
4) Exhaust camshaft pulley
5) Inlet camshaft pulley
6) Tensioner pulley

Note: There must be no slack in the belt after it has been installed.
The teeth of the belt and the teeth of the pulley must be in perfect alignment.




5. Belt tension
Loosen the tensioner bolt and apply the spring force to the belt.

Note: For reuse of the belt, do not tension the belt with other than the spring force applied. When a new belt is used, push the tension pulley in the direction of belt tension.

6. Fixing torque (Tensioner pulley)

Torque kg.m (ft.lbs.) 4.3 (31.1)

NOTE: Keep the tension pulley from turning while fastening the fixing bolt in order to prevent excessively high or low tension of the timing belt.

7. Rotate the crank shaft two turns normally and make sure that the notch of cylinder No. 1 matches the scale on the timing cover match as well as the mark on the cam pulley. If it does not match them, repeat the procedure from 1.







8. Turn the crankshaft by 60° normally and measure deflection of the belt as shown in the figure. Make sure that it is within the specified range. If the deflection is not within the specified values, repeat the procedures from 5.

9. Crankshaft pulley
^ Attach the taper face to the belt.
^ Fasten the center bolt according to the prescribed torque.

Torque kg.m (ft.lbs.) 17.0 (123.0)
Crankshaft pulley bolt socket : J-37988

10. Timing belt cover

Fasten the bolts (total 8), while paying attention to the bolt length.

Torque kg.m (ft.lbs.) 1.0 (7.2)

11. Alternator, power steering pump
Adjust the drive belt tension.

Belt tension kg (lbs.) 41 ± 10 (90 ± 20)
Using a borroughs drive belt tension gauge.