Removal and Inspection

TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION

TIMING BELT REMOVAL

1. Remove battery

CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

2. Remove engine under-cover
3. Drain engine coolant

4. Remove drive belt
Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the drive belt.

HINT: The pulley bolt for the drive belt tensioner has a left-hand thread.

5. Remove radiator reservoir tank
(a) Disconnect the coolant level sensor connector.

(b) Disconnect the following hoses:
(1) Reservoir hose from water inlet housing
(2) Reservoir hose from radiator

(c) Remove the 2 bolts and reservoir tank bracket.
(d) Remove the bolt holding the reservoir tank to the radiator.
(e) Disconnect the reservoir tank from the reservoir tank bracket, and remove the reservoir tank.

6. Remove radiator assembly
(a) Disconnect the ECT sensor connector (for cooling fan).
(b) Disconnect the ECT sensor wire clamp from the radiator fan shroud.

(c) Disconnect the following hoses:

(1) 2 oil cooler hoses (for cooling fan) from pipes

(2) 2 radiator hoses

(3) 2 oil cooler hoses (for transmission) from radiator

HINT: Plug the hose ends.

(4) Suction hose from hydraulic pump

(5) Pressure hose from hydraulic pump

(d) Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.

(e) Slightly lift the radiator, and disconnect the 2 oil cooler hoses (for cooling fan) from the hose clamp on the radiator fan shroud.
(f) Remove the radiator assembly.
(g) Remove the 2 lower radiator supports from the radiator.

7. Disconnect air conditioning (a/c) compressor from engine
(a) Disconnect the A/C compressor connector.

(b) Remove the nut, and disconnect the ground cable from the A/C compressor stay.
(c) Remove the bolt and A/C compressor stay.

(d) Remove the 2 bolts, and disconnect the A/C compressor from the engine.

HINT: Put aside the A/C compressor, and suspend it.

8. Remove intake air connector

(a) Disconnect the following hoses:
(1) Air hose from IAC valve
(2) Air hose (from air control valve on PS pump) from intake air connector

(b) Remove the bolt holding the intake air connector to the cylinder head cover.
(c) Loosen the 2 hose clamps.

(d) Disconnect the intake air connector from the throttle body and air cleaner hose, and remove the intake air connector.

9. Remove left hand ignition coil

(a) Disconnect the following connectors and cord:
(1) Ignition coil connector
(2) Noise filter connector
(3) High-tension cord

(b) Remove the 2 bolts and ignition coil.

10. Remove upper high-tension cord cover
(a) Remove the 2 bolts.
(b) Disconnect the front side claw groove of the upper cord cover from the claw of lower cord cover, and remove the upper cord cover.

11. Remove right hand engine wire cover
Remove the bolt and engine wire cover.

12. Remove left hand engine wire cover
Remove the 2 bolts and engine wire cover.

13. Remove right hand no.3 timing belt cover

(a) Disconnect the 2 air control valve hoses.
(b) Remove the 4 bolts, timing belt cover and 3 gaskets.

14. Remove left hand no.3 timing belt cover
(a) Remove the 4 bolts.
(b) Disconnect the cord grommet from the timing belt cover, and remove the timing belt cover, and 3 gaskets.
(c) Remove the cord grommet from the high-tension cord.

15. Remove high-tension cords, cord clamps and cord cover assembly

(a) Disconnect the No.2 high-tension cord from the cord clamp on the right hand front high-tension cord clamp.

(b) Remove the 2 bolts holding the right hand high-tension cord clamps to the right hand cylinder head cover.

(d) Remove the 2 bolts holding the left hand high-tension cord clamps to the left hand cylinder head cover.

(e) Remove the bolt holding the lower high-tension cord cover to the right hand ignition coil.
(f) Disconnect the high-tension cords from the spark plugs, distributor caps and right hand ignition coil.

NOTE: Pulling on or bending the cords may damage the conductor inside.

(g) Remove the high-tension cords, cord clamps and cord cover assembly.

16. Remove drive belt idler pulley
Remove the pulley bolt, cover plate and idler pulley.

17. Remove right hand no.2 timing belt cover

(a) Except Calif.:
Disconnect the camshaft position sensor connector from the ignition coil bracket.

(b) Disconnect the camshaft position sensor wire from the timing belt cover.

(c) Remove the 5 bolts.
(d) Remove the connector grommet from the timing belt cover.
(e) Disconnect the camshaft position sensor wire clamp from the timing belt cover.
(f) Remove the timing belt cover and 4 gaskets.

18. Remove left hand no.2 timing belt cover
(a) Disconnect the camshaft position sensor wire from the clamp on the timing belt cover.
(b) Disconnect the camshaft position sensor connector.
(c) Remove the 3 bolts.
(d) Remove the connector grommet from the liming belt cover.
(e) Remove the timing belt cover and 2 gaskets.

19. Remove distributor caps
Loosen the 3 bolts, and remove the distributor cap. Remove the 2 distributor caps.

HINT: Arrange the distributor caps (right hand side and left hand side).

20. Remove distributor rotors
Loosen the 2 bolts, and remove the distributor rotor.
Remove the 2 distributor rotors.

HINT: Arrange the distributor rotors (right hand side and left hand side).

21. Remove distributor housings
(a) right hand Distributor Housing:
Disconnect the camshaft position sensor connector.

(b) Remove the 3 bolts and distributor housing. Remove the 2 distributor housings.

22. Remove generator
(a) Disconnect the generator connector.
(b) Remove the cap and nut, and disconnect the generator wire.
(c) Remove the bolt, and disconnect the transmission oil cooler pipe bracket from the generator.
(d) Remove the nut and generator.

23. Remove drive belt tensioner
Remove the bolt, 2 nuts and belt tensioner.

24. Remove spark plugs
Using a 16 mm plug wrench, remove the 8 spark plugs.

25. If re-using timing belt, check installation marks on timing belt
Check that there are 4 installation marks on the timing belt by turning the crankshaft pulley as shown in the illustration.

HINT: If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part.

26. Set no.1 cylinder to TDC/compression
(a) Turn the crankshaft pulley and align its groove with timing mark -0 of the No.1 timing belt cover.

(b) Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned. If not, turn the crankshaft 1 revolution (3600).

27. Remove timing belt tensioner

HINT:
- When re-using timing belt:

If the installation marks have disappeared, before remove the timing belt, place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys, and place a new installation mark on the timing belt to match the end of the hydraulic pump.

- When replacing timing belt tensioner only:
To avoid meshing of the timing pulley and timing belt, secure one of them with string. Place match- marks on the timing belt and right hand camshaft timing pulley. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.

28. Disconnect timing belt from camshaft timing pulleys

(a) Using SST, loosen the tension spring between the left hand and right hand camshaft timing pulleys by slightly turning the left hand camshaft timing pulley clockwise. SST 09960-10010
(b) Disconnect the timing belt from the camshaft timing pulleys.

29. Remove camshaft timing pulleys
Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. SST 09960-10010

30. Remove crankshaft pulley

(a) Using SST remove the pulley bolt. SST 09950-50010

(b) Using SST, remove the crankshaft pulley. SST 09950-50010

31. Remove hydraulic pump

HINT: (When re-using timing belt): Before removing the hydraulic pump, using the crankshaft pulley bolt, turn the crankshaft pulley and align the installation mark of the timing belt with the end of the hydraulic pump.

(a) Disconnect the solenoid valve connector.
(b) Remove the 2 bolts and 2 nuts.
(c) Disconnect the crankshaft position sensor wire clamp.
(d) Remove the hydraulic pump.

32. Remove no.1 timing belt cover
Remove the 4 bolts, timing belt cover and gasket.

33. Remove timing belt cover spacer
Remove the belt cover spacer and gasket.

34. Remove timing belt guide (crankshaft angle sensor plate)
35. Remove timing belt

HINT: (When re-using timing belt): If the installation marks have disappeared, place a new installation mark on the timing belt to the match the dot mark of the crankshaft timing pulley.

36. Remove no.2 idler pulley
Remove the bolt and idler pulley.

37. Remove no.1 idler pulley
Using a 1 0 mm hexagon wrench, remove the bolt, idler pulley and plate washer.

38. Remove crankshaft timing pulley
Using SST, remove the timing pulley. SST 09950-50010

TIMING BELT COMPONENTS INSPECTION

1. Inspect timing belt

NOTE:

- Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

If there are any defects as shown in the illustration, check the following points:

(a) Premature parting
- Check the proper installation.
- Check the timing cover gasket for damage and proper installation.

(b) If the belt teeth are cracked or damaged, check to see if either camshaft or water pump is locked.

(c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock.

(d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.

(e) If there is noticeable wear on the belt teeth. check the timing cover for damage, gasket has been installed correctly, and the foreign material on the pulley teeth. If necessary, replace the timing belt.

2. Inspect idler pulleys
Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.

3. Inspect timing belt tensioner

(a) Visually check tensioner for leakage.

HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner.

(b) Hold the tensioner with both hands, and push the push rod firmly against floor or wall to check that it doesn't move.
If push rod moves, replace the tensioner.

(c) Measure the protrusion of the push rod from the housing end.

Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 in.)

If the protrusion is not as specified, replace the tensioner.