Timing Belt Installation

Timing Belt Inspection:

Inspecting Timing belt for wear, damage, and irregularities.

Checking Idler Pulleys And Spring Free Length:

Inspect Idler Pulleys by turning and checking for smoothness/ Replace if necessary. The length of the tensioner spring should be 51.93 mm (2.0445 in.). If not as specified, replace with a new one.

NOTE: If original timing belt is used, align marks placed during removal and install timing belt with arrow pointing in direction of engine rotation.
a. If a new timing belt is to be used, install timing belt with numbers and letters that can be read from the rear of the engine.

Removing Timing Belt:

1. Install crankshaft timing pulley, using SST 09214-60010 and a hammer.

Installing Oil Pump Drive Pulley:

2. Using SST 09612-24012 or equivalent to hold the oil pump drive
pulley, install and torque the mount nut. Torque the nut to 47 Nm (34 ft lb).
3. Install no. 2 idler pulley and torque the nut to 37 Nm (27 ft lb).

Installing Injection Pump Drive Pulley:

4. Install injection pump drive pulley.
a. Install the injection pump drive pulley over the injection pump key.
b. Using SST 09278-54011 or equivalent to hold the drive pulley, install and torque the mount bolt to 64 Nm (47 ft lb). Do not use an impact wrench.

Installing No. 1 Idler Pulley:

5. Temporarily install the No. 1 idler pulley.
a. Install the No. 1 idler pulley and finger tighten the pulley mount bolt.
b. Install the pulley guide bolt, then torque the bolt to 7.4 Nm (65 in lb). Check that the idler pulley bracket can be moved to the left and right by hand.

Installing Camshaft Timing Pulley:

6. Install the camshaft timing pulley.
a. Align the camshaft knock pin with the camshaft timing pulley and install the timing pulley.
b. Using SST 09278-54011 or equivalent, install and torque the mount bolt with the plate washer. Torque the bolt to 98 Nm (72 ft lb).
7. Install timing belt.
CAUTION: The engine should be cold.

Installing Timing Belt:

a. Align the line mark of the camshaft timing pulley with the top end of the cylinder head.
NOTE: Do not align the cylinder head cover with the boss.
b. Align the grooves of the crankshaft timing pulley and oil pump.
c. Align the cavity of the injection pump drive pulley with the line mark on the water pump.
NOTE: Secure the injection pump drive pulley in place until the timing belt is installed because the drive pulley will not come on rest by itself at the matchmark position.
d. Install the timing belt to the camshaft timing pulley.
NOTE: Install a new belt so the numbers and letters can be read from the rear end of the engine.

Installing Timing Belt To Pump Drive Pulley:

e. Install the timing belt to the pump drive pulley while holding the pulley stationary with a wrench.
CAUTION: Be sure the timing belt is securely meshed and not loose.

Installing Timing Belt To Water Pump And Crankshaft Timing Pulley:

f. Install the timing belt to the water pump pulley and crankshaft timing pulley.

Installing Timing Belt To No. 2 Idler Pulley And Oil Pump Pulley:

g. Install the timing belt to the No. 2 idler pulley and oil pump pulley.

Installing Tensioner Spring:

h. Using a screwdriver, install the tension spring.
NOTE: Do not pinch the tension spring with pliers or such.

Turing Crankshaft Pulley:

i. Using the crankshaft pulley mount bolt, turn the crankshaft 2 revolutions from TDC to TDC. Always turn the crankshaft clockwise.

Checking Alignment Marks:

j. Confirm that each pulley aligns with the marks. If the marks do not align, remove the timing belt and re-install it.

Torquing No. 1 Idler Pulley Mounting Bolt:

k. Torque the No. 1 idler pulley mount bolt to 37 Nm (27 ft lb). Do not move the idler pulley bracket while tightening the pulley bolt.

Installing Right Engine Mount:

8. Install the right engine mounting bracket with six bolts, and torque the bolts.
a. 10 mm bolt head torque: 37 Nm (27 ft lb)
b. 12 mm bolt head torque: 64 Nm (47 ft lb)

Connecting Engine Mounting Center Member:

9. Connect the right engine mounting to the right mounting bracket, then lower the engine and remove the jack.
10. Connect the engine mounting center member with the four bolts, then torque the bolts to 39 Nm (29 ft lb).

Installing Belt Guide And No. 1 Timing Belt Cover:

11. Install the belt guide and No. 1 timing belt cover with the five bolts.

Installing Crankshaft Pulley:

12. Using SST 09214-60010 or equivalent and a hammer, drive in the crankshaft pulley.

Torquing Pulley Set Bolt:

13. Using SST 09213-14010 and 09330-00020, torque the set bolt to 98 Nm (72 ft lb).

Installing No. 2 Timing Belt Cover:

14. Install the No. 2 timing belt cover and gasket with the three clips and five bolts.

Disconnecting Vane Pump:

15. Connect the vane pump (if equipped with power steering) with the three bolts, then torque the bolts to 39 Nm (29 ft lb).
16. Install drive belt and pulley.
a. Install the drive pulley and woodruff key.
b. Install the drive belt.
c. Turn the adjusting bolt until the belt tension is at specified value, and then torque the idler pulley nut to 38 Nm (28 ft lb).
Drive Belt tension:
New belt: 160±20 lb
Used belt: 100±20 lb

NOTE: New belt refers to a brand new belt which has never been used.
Used belt refers to a belt which has been used on a running engine for 5 minutes or more.

Checking Belt For Proper Alignment Into Groove:

After installing the drive belt, check that it fits properly in the ribbed grooves.

d. Push down on the drive belt to hold the pulley in place and torque the pulley set nut to 43 Nm (32 ft lb).
17. Install the engine under cover.