Timing Belt: Service and Repair

TIMING BELT

Components:

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE ENGINE ROOM SIDE COVER LH
5. REMOVE NO.1 AIR CLEANER INLET
a. Remove the bolt and No.1 air cleaner inlet.

6. DRAIN ENGINE COOLANT
7. REMOVE V-BANK COVER
8. REMOVE INTAKE AIR CONNECTOR PIPE
9. REMOVE ENGINE UNDER COVER
10. DISCONNECT RADIATOR HOSE INLET
11. DISCONNECT RADIATOR HOSE OUTLET
12. DISCONNECT NO.1 OIL COOLER INLET TUBE
13. DISCONNECT NO.1 OIL COOLER OUTLET TUBE
14. REMOVE AIR CLEANER ASSEMBLY
15. REMOVE RADIATOR ASSEMBLY
a. Removal the radiator.

16. REMOVE FAN AND GENERATOR V-BELT
17. REMOVE GENERATOR ASSEMBLY

18. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY
a. Remove the 3 bolts, nut, stay and wire bracket, and disconnect the cooler compressor.

HINT: If is not necessary to completely remove the compressor. With the low pressure and high pressure hoses connected to the compressor, hang the compressor (with the magnetic clutch) on the vehicle body with a rope.

19. REMOVE NO.3 TIMING BELT COVER SUB-ASSEMBLY RH
a. Remove the cap nut, 3 bolts, timing belt cover and gasket.

20. REMOVE NO.3 TIMING BELT COVER SUB-ASSEMBLY LH
a. Remove the cap nut and disconnect the No.3 water by-pass pipe from the timing belt cover.
b. Disconnect the 2 water by-pass hoses from the No.3 water by-pass pipe.

c. Disconnect the engine wire from the 2 wire clamps.
d. Disconnect the camshaft position sensor connector.
e. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
f. Remove the wire grommet from the timing belt cover.
g. Remove the 4 bolts.
h. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
i. Disconnect the wire clamp for the sensor from the timing belt cover.
j. Remove the connector holder from the sensor connector.
k. Remove the timing belt cover.

21. REMOVE NO.2 TIMING BELT COVER SUB-ASSEMBLY
a. Remove the 2 bolts and timing belt cover.

22. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and belt tensioner.

23. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY
24. REMOVE NO.1 IDLER PULLEY SUB-ASSEMBLY
a. Remove the 2 bolts, 2 nuts and idler pulley.

25. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Using SST, remove the damper bolt.
SST 09213-70011, 09330-00021

b. Using SST, remove the damper.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)

26. REMOVE NO.1 TIMING BELT COVER
a. Remove the 4 bolts and cover.

27. REMOVE NO.1 CRANKSHAFT POSITION SENSOR PLATE

28. REMOVE TIMING BELT
a. If planning to reuse the belt, check the installation marks on the timing belt.
(1) Check that there are 3 installation marks on the belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, place new installation marks on the belt before removing each part.

b. Set the No.1 cylinder to approximately 50° BTDC/compression.
(1) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body

(2) Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 revolution (360°).

(3) Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 45°.

NOTICE: With the timing belt disengaged, the crankshaft damper must be at the correct angle to avoid damage in a later step.

c. Alternately loosen the 2 bolts. Then remove the 2 bolts, belt tensioner and dust boot.

d. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise.
SST 09960-10010 (09962-01000, 09963-00350)
e. Disconnect the belt from the No.1 timing belt idler, and remove the belt.

INSTALLATION
1. INSTALL TIMING BELT
a. Check the No.1 and No.2 belt idlers.
(1) Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler.
(2) Check that the idler turns smoothly.
If necessary, replace the idler.

b. Check the water pump.
(1) Visually check the air hole and water hole for coolant leakage.
If leakage is found, replace the water pump and belt.
(2) Turn the pulley, and check that the water pump bearing moves smoothly and quietly.
If necessary, replace the water pump.
c. Remove any oil or water on the crankshaft, oil pump pulley, water pump pulley, No.1 and No.2 idler. Keep them clean.

NOTICE: Only wipe the pulleys. Do not use any cleansing agents on the pulleys.

d. Set the No.1 cylinder to TDC/compression.
(1) Turn the hexagon head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

HINT: Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier. Camshaft timing pulley of LH bank: 1/2 of a tooth Camshaft timing pulley of RH bank: 1 tooth

(2) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body

(3) Remove any oil or water on each pullet. Keep them clean.

NOTICE: Only wipe the pulleys. Do not use cleaning agents on the pulleys.

(4) Face the front mark (arrow) on the belt forward.
(5) Connect the belt to the crankshaft timing pulley. Align the installation mark on the belt with the timing mark of the crankshaft timing pulley
(6) Connect the belt to the No.2 idler.
(7) Connect the belt to the camshaft timing pulley (LH bank). Align the installation mark on the belt with the timing mark of the camshaft timing pulley
(8) Connect the belt to the water pump pulley.
(9) Connect the belt to the camshaft timing pulley (RH bank). Align the installation mark on the belt with the timing mark of the camshaft timing pulley
(10) Connect the timing belt to the No.1 idler.

e. Set the belt tensioner.
(1) Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbs.) of pressure.
(2) Align the holes of the push rod and housing. Pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
(3) Release the press.
(4) Install the dust boot to the belt tensioner.

f. Install the belt tensioner.
(1) Temporarily install the belt tensioner with the 2 bolts.
(2) Alternately tighten the 2 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
(3) Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.

g. Check the valve timing.
(1) Using the crankshaft damper bolt, slowly turn the crankshaft timing pulley 2 revolutions from TDC to TDC.

NOTICE: Always turn the crankshaft pulley clockwise.

(2) Check that each pulley aligns with the timing marks as shown in the illustration.
If the pulley and timing marks do not align, remove the belt and reinstall it.
(3) Remove the crankshaft damper bolt.

2. INSTALL NO.1 CRANKSHAFT POSITION SENSOR PLATE
a. Install the sensor plate as shown in the illustration.

NOTICE: Be careful of the installation direction.

3. INSTALL NO.1 TIMING BELT COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

4. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Align the damper set key with the key groove of the crankshaft damper.
b. Using SST and a hammer, tap in the damper.
SST 09223-46011

c. Using SST, install the damper bolt.
SST 09213-70011, 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)

5. INSTALL NO.1 IDLER PULLEY SUB-ASSEMBLY
a. Install the idler with the 2 bolts and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.) for 12 mm head
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head
Bolt length:
106 mm (4.17 inch) for 12 mm head bolt A
114 mm (4.49 inch) for 14 mm head bolt B

6. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY
7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 15.5 Nm (158 kgf-cm, 11 ft. lbs.)

HINT: Use a bolt that is 106 mm (4.17 inch) in length.

8. INSTALL NO.2 TIMING BELT COVER SUB-ASSEMBLY
a. Set the No.2 cover by matching the claws and pin with each part.
b. Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

HINT: Use bolts that are 106 mm (4.17 inch) in length.

9. INSTALL NO.3 TIMING BELT COVER SUB-ASSEMBLY LH
a. Install the gasket to the cover.
b. Pass the camshaft position sensor wire through the cover hole.
c. Install the cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
d. Install the wire grommet to the cover.
e. Install the sensor connector to the sensor holder.
f. Connect the sensor connector.
g. Install the sensor wire to the wire clamp on the cover.
h. Install the engine wire to the 2 wire clamps on the cover.

i. Connect the 2 water by-pass hoses as shown in the illustration.
j. Install the No.3 water by-pass pipe to the cover with the cap nut.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

10. INSTALL NO.3 TIMING BELT COVER SUB-ASSEMBLY RH
a. Install the gasket to the cover.
b. Install the cover with the cap nut and 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

11. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY
a. Set the cooler compressor to the engine for nuts

12. INSTALL GENERATOR ASSEMBLY
13. INSTALL FAN AND GENERATOR V-BELT
14. INSTALL RADIATOR ASSEMBLY
a. Install the radiator.

15. CONNECT NO.1 OIL COOLER OUTLET TUBE
16. CONNECT NO.1 OIL COOLER INLET TUBE
17. CONNECT RADIATOR HOSE OUTLET
18. CONNECT RADIATOR HOSE INLET
19. INSTALL AIR CLEANER ASSEMBLY
a. Install the air cleaner assembly with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

b. Connect the MAF meter connector and clamp to the air cleaner.

20. INSTALL NO.1 AIR CLEANER INLET
a. Install the No.1 air cleaner inlet and bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

21. INSTALL INTAKE AIR CONNECTOR PIPE
22. INSTALL V-BANK COVER
a. Install the V-bank cover with the 2 nuts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

23. REMOVE ENGINE ROOM SIDE COVER LH
24. REMOVE ENGINE ROOM SIDE COVER RH
25. REMOVE COOL AIR INTAKE DUCT SEAL
26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
27. PERFORM INITIALIZATION
a. Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

28. ADD ENGINE COOLANT
29. CHECK FOR ENGINE COOLANT LEAKS
a. Check for engine coolant leaks.

30. INSTALL ENGINE UNDER COVER