Timing Belt: Service and Repair
TIMING BELTREMOVAL AND INSTALLATION
CAUTION: If the vehicle is equipped with the Brembo(TM) disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal & Post-installation Operation:
Removal Steps 1-10:
Removal Steps 11-20 & Required Special Tools:
REMOVAL SERVICE POINTS
[[A]] VALVE TIMING BELT REMOVAL
CAUTION: Never turn the crankshaft counterclockwise.
1. Turn the crankshaft clockwise, align each timing mark to set number 1 cylinder to TDC of its compression stroke.
2. Remove the timing belt under cover rubber plug and then set the special tool MD998738.
CAUTION: The special tool MD998738 can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool MD998738 may bend.
3. Screw in the special tool MD998738 until it comes in contact with the timing belt tensioner arm.
4. Gradually screw in the special tool MD998738. Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjuster cylinder set hole B.
5. Insert a wire or pin in the set hole.
CAUTION: For reinstallation of the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
6. After removal of adjusting bolt special tool MD998738, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.
[[B]] POWER STEERING OIL PUMP, BRACKET AND RESERVOIR ASSEMBLY REMOVAL
With the hose installed, remove the power steering oil pump assembly from the bracket.
NOTE: Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balancer timing belt.
[[C]] CRANKSHAFT CAMSHAFT DRIVE SPROCKET REMOVAL
1. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385.
2. Loosen the crankshaft pulley center bolt and remove the crankshaft camshaft drive sprocket.
[[D]] BALANCER TIMING BELT REMOVAL
CAUTION: For reinstallation of the balancer timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
INSTALLATION SERVICE POINTS
]]A[[ BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION
1. Ensure that the crankshaft balancer shaft drive sprocket timing marks and balancer shaft sprocket timing marks are aligned.
2. Install the balancer timing belt on the crankshaft balancer shaft drive sprocket and balancer shaft sprocket. There should be no slack on the tension side.
3. Assemble and temporarily fix the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front-side of the engine.
4. Adjust the balancer timing belt tension.
]]B[[ BALANCER TIMING BELT TENSION ADJUSTMENT
CAUTION: When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate with the bolts can cause excessive tension of the belt.
1. With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. Apply pressure of [3.0 ± 0.4 Nm (26 ± 4 inch lbs.)] to the balancer timing belt. Tighten the assembling bolt to the standard torque. Then, fix the balancer timing belt tensioner.
Tightening torque: 19 ± 3 Nm (14 ± 2 ft. lbs.)
2. Turn the crankshaft clockwise two turns to set number 1 cylinder to TDC of its compression stroke and check that the sprocket timing marks are aligned.
3. Apply a pressure of approximately 100N (22 pounds) at the center (arrow area) between the sprocket as shown, then inspect whether the belt deflection is within the standard value.
Standard value:
At adjustment: 5 - 7 mm (0.20 - 0.27 inch)
At replacement: 5 - 7 mm (0.20 - 0.27 inch)
4. If not within the standard value, adjust the belt tension again.
]]C[[ CRANKSHAFT ANGLE SENSING BLADE/CRANKSHAFT CAMSHAFT DRIVE SPROCKET INSTALLATION
1. Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive sprocket and crankshaft pulley washer as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown.
3. Place the larger chamfer side of the crank shaft pulley washer in the direction shown and then assemble on the crankshaft pulley center bolt.
4. Apply some engine oil to the crankshaft pulley center bolt bearing surface and screw.
5. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385 in the same manner as removal.
6. Tighten the crankshaft pulley center bolts to the specified torque.
Tightening torque: 167 Nm (123 ft. lbs.)
]]D[[ TIMING BELT TENSIONER ADJUSTER INSTALLATION
1. Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended.
CAUTION: If the compression is too fast, the procedure may damage the rod.
1. Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder.
2. Insert a wire or pin into the aligned set hole.
NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the standard torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)
]]E[[ TIMING BELT TENSIONER PULLEY INSTALLATION
Temporarily tighten the timing belt tensioner pulley as shown.
]]F[[ VALVE TIMING BELT INSTALLATION
1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
2. After aligning the timing marks of the engine oil pump sprocket, remove the cylinder block plug and insert a Phillips screw driver with a shaft diameter of 8 mm (0.31 inch) through the plug hole to check that the shaft of the screw driver can be inserted for 60 mm (2.36 inches) or more. If the screw driver makes contact with the balancer shaft and can be inserted for only 20 - 25 mm (0.79 - 0.98 inch), turn the engine oil pump sprocket for one round and align timing marks again to check that screw driver can be inserted for 60 mm (2.36 inches) or more. Do not take the screw driver out before completing installation of the valve timing belt.
3. Install the valve timing belt as follows:
1. Pass the valve timing belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley in that order.
2. Pass the timing belt around the camshaft sprocket (exhaust side), and hold it with paper clamps in the location shown in the figure.
3. Use a wrench to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the timing belt around the camshaft sprocket (inlet side).
4. Pass the timing belt around the tensioner pulley.
CAUTION: Install the valve timing belt. Then apply reverse rotation (counterclockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is aligned while the tension side of the belt is tight.
5. Remove the two paper clamps.
4. Turn the timing belt tensioner in the direction shown using special tool MD998767 to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley.
5. Check that the timing marks are aligned.
6. Remove the Phillips screw driver inserted in Step 2 above, then assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified torque.
Tightening torque: 30 ± 3 Nm (23 ± 2 ft. lbs.)
8. Adjust the valve timing belt tension.
]]G[[ VALVE TIMING BELT TENSION ADJUSTMENT
1. Set special tool MD998738 when removing the valve timing belt.
CAUTION: Always screw in special tool MD998738 by hand. Use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster.
2. Gradually screw in special tool MD998738 until the wire or pin inserted in the timing belt tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 turn counterclockwise.
4. Turn the crankshaft in the clockwise direction until you align each timing mark to set number 1 cylinder to TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting bolt.
CAUTION: When tightening the mounting bolts, ensure that the timing belt tensioner pulley does not rotate with the bolts. Allowing it to rotate with the bolts can cause deficient tension of the belt.
6. With special tool MD998767 and torque wrench, apply tension torque [3.5 Nm (31 inch lbs.)], and tighten the timing belt tensioner pulley mounting bolt to the specified torque.
Tightening torque: 48 ± 5 Nm (36 ± 3 ft. lbs.)
7. Remove wire or pin inserted to timing belt tensioner.
8. Remove the special tool MD998738, and install the rubber plug to the timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.
10. Insert wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin.
If the projection of timing belt tensioner adjuster rod is within the standard value, appropriate tension is applied.
Standard value (A): 3.8 - 4.5 mm (0.15 - 0.17 inch)
11. If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension.
CAUTION: Always check the tightening torque of the crank shaft pulley center bolt when turning the crack shaft pulley center bolt counterclockwise. Re-tighten if it is loose.
12. Check again that the timing marks on sprockets are aligned.
INSPECTION
TIMING BELT TENSIONER ADJUSTER CHECK
1. Check for oil leak from seal, and replace it if leak is detected.
2. Check for wear or damage at the top of the rod. Replace it, if required.
3. Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.g. cylinder block) under a pressure of 98 - 196 N (22 - 44 pounds) to measure the movement of the rod.
Standard value: Within 1 mm (0.039 inch)
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
4. If the measured value is out of the standard value, replace the timing belt tensioner adjuster.
BALANCER TIMING BELT TENSION CHECK
Check the balancer timing belt tension as follows:
1. Apply a pressure of approximately 100 N (22 pounds) at the center (arrow area) between the sprocket as shown then inspect whether the deflection is within the standard value.
Standard value: 5 - 10 mm (0.20 - 0.39 inch)
2. If not within the standard value, adjust the belt tension.