Timing Belt: Service and Repair

REMOVAL OF TIMING BELT
1. REMOVE RADIATOR
2. REMOVE SPARK PLUGS

3 REMOVE WATER OUTLET
Remove the two bolts, water outlet and thermostat with the gasket.
4. REMOVE A/C BELT

5. REMOVE FAN AND ALTERNATOR DRIVE BELT
6. REMOVE PS BELT

7. REMOVE NO.3 TIMING BELT COVER
Remove the five bolts, nut and No.3 timing belt cover with the gasket.

8. SET NO.1 CYLINDER AT TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with the "0" mark on the No.1 timing belt cover.

(b) Check that the matchmarks on the camshaft timing pulleys and No.2 timing belt cover are aligned. If not, turn the crankshaft pulley one complete revolution.

9. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS

NOTE: If reusing the timing belt, draw a direction arrow on the belt (in direction of engine revolution).

(a) Loosen the idler pulley bolt and shift it left as far as it will go with a screwdriver and wrench.
(b) Temporarily tighten the set bolt and then relieve the timing belt tension.
(c) Remove the belt from the camshaft timing pulleys.

NOTE:
- Support the belt so the meshing of the crankshaft timing pulley and timing belt does not shift. Be careful not to drop anything inside the timing belt cover.
- Do not allow the belt to come into contact with oil, water and dust.

10. REMOVE CAMSHAFT TIMING PULLEYS

Using SST to hold the pulley, remove the pulley bolt, timing pulley and match pin. SST 09278-54012

CAUTION: Do not make use of the timing belt tension when removing and installing the pulley bolts.

11. REMOVE CRANKSHAFT PULLEY

(a) Using SST to hold the crankshaft pulley, loosen the pulley bolt. SST 09213-70010 and 09330-00021
(b) Remove SST and pulley bolt.

13. REMOVE NO.1 TIMING BELT COVER
(a) Remove the A/C compressor without disconnecting hoses (d).
(b) Remove the nine bolts, nut, A/C idler pulley bracket, compressor bracket and No.1 timing belt cover.
14. REMOVE TIMING BELT
15. REMOVE IDLER PULLEY AND TENSION SPRING

16. REMOVE CRANKSHAFT TIMING PULLEY
Using SST and socket wrench, remove the crankshaft timing pulley. SST 09213-60017

17. REMOVE OIL PUMP DRIVE PULLEY
Using a screwdriver to hold the pulley, remove the pulley bolt and pulley.

INSTALLATION OF TIMING BELT

1. IN STALL OIL PUMP DRIVE PULLEY
(a) Install the pulley and bolt.
(b) Using a screwdriver to hold the pulley, torque the pulley bolt.
Torque: 220 kg-cm (16 ft-lb, 22 N.m)

2. INSTALL CRANKSHAFT TIMING PULLEY
Using SST and hammer, drive in the pulley. SST 09214-60010

3. TEMPORARILY INSTALL IDLER PULLEY AND TENSION SPRING
(a) Install the idler pulley and tension spring.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
(b) Pry the idler pulley toward the left as far as it will go and temporarily tighten it.

NOTE: Remove any oil or water on the idler pulley and keep it clean.

4. TEMPORARILY INSTALL TIMING BELT

CAUTION: The engine should be cold.

NOTE: If reusing the timing belt, install it with the rotation direction mark pointing in the same direction as before disassembly. Install the timing belt on the crankshaft timing pulley, oil pump drive pulley and idler pulley

5. INSTALL NO.1 TIMING BELT COVER
(a) Install the No.1 timing timing belt cover, A/C compressor bracket and idler pulley bracket with the nine bolts and nut.
(b) Install the A/C compressor.
6. INSTALL PS AIR PIPE

7. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley.
(b) Install the pulley.
bolt.SST 09213-70010 and 09330-00021
Torque: 2,700 kg-cm (195 ft-lb, 265 N.m)

8. SET NO.1 CYLINDER TO TDC/COMPRESSION OF CRANKSHAFT
Turn the crankshaft pulley and align its groove with the "0" mark on the No.1 timing belt cover.

9. INSTALL CAMSHAFT TIMING PULLEYS
(a) Align the timing pulley matchmark with the No.2 timing belt cover matchmark.
(b) Install the timing pulley.
(c) Install the pin to the hole.

NOTE: When replacing the camshaft or the camshaft timing pulley align the center holes of the camshaft and timing pulleys, as shown in the illustration and insert the straight pin.
- When resuing the camshaft or camshaft timing pulleys:
Checking that the straight pin hole position is in the same position it was at disassembly, insert the straight pin.
(d) Install the washer and pulley bolt.

(e) Using SST 09278-54012
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
(f) Check that the matchmarks on the camshaft timing pulley are aligned with those on the No.2 timing belt cover.

10. INSTALL TIMING BELT
(a) Install the timing belt to the IN side and EX side.
(b) Loosen the idler pulley bolt, and torque the idler pulley bolt.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)

NOTE: Make sure that the timing belt tension at A is equal to that at B. If not, readjust with the idler pulley.

(c) Turn the crankshaft pulley two revolutions clockwise from TDC to TDC.
(d) Check that the matchmarks on the camshaft timing pulley are aligned with those on the No.2 timing belt cover.

11. CHECK TIMING BELT TENSION
(a) Turn both the intake and exhaust camshaft pulleys inward at the same time to slacken the timing belt at position A.

(b) Measure the timing belt deflection as shown.
Belt deflection at 2 - 3 kg (4.4 - 6.6 lb, 20 - 29 N):
Cold Used belt 5 - 7 mm (0.20-0.28 in.)
New belt 4 - 6 mm (0.16-0.24 in.)
Hot (Referance) 3 - 5 mm (0.12-0.20 in.)
If the measurement is not within in limit, adjust by the idler pulley.

12. INSTALL NO.3 TIMING BELT COVER
Install a gasket and the belt cover with the five bolts as shown.
13. INSTALL PS BELT

14. INSTALL ALTERNATOR DRIVE BELT AND FAN
Torque: Fan 55 kg-cm (48 in.-lb, 5.4 N.m)
Adjusting bolt 130 kg-cm (9 ft-lb, 5.4 N.m)
15. INSTALL A/C BELT

16. INSTALL WATER OUTLET
Install the thermostat with gasket and water outlet with the two bolts.
17. INSTALL SPARK PLUGS
18. INSTALL RADIATOR
19. INSTALL NO.1 AIR CLEANER HOSE WITH INTAKE AIR CONNECTOR PIPE
20. START ENGINE
Warm up the engine and inspect for leaks.
21. ROADTEST
Road test vehicle.
22. RECHECK COOLANT LEVEL