Timing Belt

COMPONENT


The Contents of This Article Reflects TSB 18-135-09 Dated 02/02/2009.


REMOVAL
TIMING BELT
1. Remove the V-belts.
2. Remove the crank pulley.
3. Remove the timing belt cover.














4. Remove the timing belt guide. (With timing belt guide model)
5. If the alignment mark or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below.





a Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam sprocket (RH) with notches of timing belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET











b Using white paint, put alignment and/or arrow marks on the timing belts in relation to the cam sprockets.





6. Remove the belt idler (A).
7. Remove the timing belt.

CAUTION: After the timing belt has been removed, never rotate the intake and exhaust cam sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.

BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY





1. Remove the belt idler (B) and (C).





2. Remove the belt idler No. 2.





3. Remove the automatic belt tension adjuster assembly.

INSTALLATION
AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
1. Preparation for installation of automatic belt tension adjuster assembly.

CAUTION:
^ Always use a vertical type pressing tool to move the adjuster rod down.
^ Do not use a lateral type vise.
^ Push the adjuster rod vertically.
^ Press-in the push adjuster rod gradually taking more than three minutes.
^ Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbs.).
^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder.
^ Do not release the press pressure until stopper pin is completely inserted.

a Attach the automatic belt tension adjuster assembly to the vertical pressing tool.





b Slowly move the adjuster rod down with a pressure of more than 165 N (16.8 kgf, 37.1 lbs.) until the adjuster rod is aligned with the stopper pin hole in the cylinder.





c With a 2 mm (0.08 inch) dia. stopper pin or a 2 mm (0.08 inch) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod.





2. Install the automatic belt tension adjuster assembly.





3. Install the belt idler No. 2.





4. Install the belt idlers.

TIMING BELT
1. Preparation for installation of automatic belt tension adjuster assembly.
2. Crankshaft and cam sprocket alignment





a Align the mark (A) on crank sprocket with the mark on oil pump cover at cylinder block.





b Align single line mark (A) on the exhaust cam sprocket (RH) with notch (B) on timing belt cover.





c Align single line mark (A) on the intake cam sprocket (RH) with notch (B) on timing belt cover. (Ensure double lines (C) on intake and exhaust cam sprockets are aligned.)





d Align single line mark (A) on exhaust cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).





e Align single line mark (A) on intake cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Ensure double lines (C) on intake and exhaust cam sprockets are aligned.





f Ensure that the cam and crank sprockets are positioned properly.

CAUTION:
^ Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, their heads will interfere with each other' resulting in bent valves.
^ When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push the intake and exhaust valves down. (Under this condition, all valves remain uplifted.)
^ When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshafts (LH) are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Camshafts (RH) are held so that their cams do not push valves down.
^ Camshafts (LH) must be rotated from the "zero-lift" position to the position where the timing belt is to be installed with the smallest possible angle, in order to prevent mutual interference of intake and exhaust valve heads.





^ Do not allow the camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.





3. Installation of timing belt:
Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in the figure. While aligning marks, position the timing belt properly.

CAUTION:
^ Disengagement of more than three timing belt teeth may result in interference between valve and piston.
^ Ensure the belt's rotating direction is correct.





4. Install the belt idlers.
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)

NOTE: Make sure that the marks on the timing belt and sprockets are aligned.

5. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
6. Install the timing belt guide. (Model with timing belt guide)
a Temporarily tighten the bolts.














b Check and adjust the clearance between timing belt and timing belt guide.














c Tighten the bolt.
7. Install the timing belt cover.
8. Install the crank pulley.
9. Install the V-belts.

INSPECTION
TIMING BELT
1. Check the timing belt teeth for breaks, cracks and wear. If any fault is found, replace the timing belt.
2. Check the condition of the backside of timing belt. If cracks are found, replace the timing belt.





CAUTION:
^ Be careful not to let oil, grease or engine coolant contact the belt. Remove quickly and thoroughly if this happens.
^ Do not bend the timing belt sharply.

AUTOMATIC BELT TENSION ADJUSTER
1. Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly.

NOTE: Slight trace of oil at rod's oil seal does not indicate a problem.

2. Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lbs.) is applied to it. This is to check adjuster rod stiffness.
3. If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lbs.), check it using the following procedures:
a Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this operation two to three times.
b With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lbs.) to it. Check the adjuster rod stiffness.
c If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one.

CAUTION:
^ Always use a vertical type pressing tool to move the adjuster rod down.
^ Do not use a lateral type vise.
^ Push the adjuster rod vertically.
^ Press-in the push adjuster rod gradually taking more than three minutes.
^ Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbs.).
^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder.





4. Measure the amount of rod protrusion beyond the body. If it is not within specifications, replace with a new one.

BELT TENSION PULLEY
1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty.
2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3. Check the belt tension pulley for grease leakage.

BELT IDLER
1. Check the belt idler for smooth rotation. Replace if noise or excessive play occurs.
2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check the belt idler for grease leakage.