Timing Belt: Service and Repair
REMOVAL SERVICE POINTS
CRANKSHAFT PULLEY REMOVAL
Use the special tools to remove the crankshaft pulley from the crankshaft.
Caution: Use only the specified special tools, or the pulley damper could be damaged.
ENGINE SUPPORT BRACKET REMOVAL
Spraying lubricant, slowly remove the bolt (reamer bolt) indicated by the arrow.
Caution: Keep in mind that the reamer bolt is sometimes heat seized on the engine support bracket.
Do not disconnect hoses to remove the power steering oil pump and bracket assembly.
NOTE: Use wire or similar material to suspend the removed oil pump. Check that nothing around it will be damaged during removal/ installation of the timing belt.
(1) Use the special tool to align the timing marks.
(2) Chalk an arrow indicating the direction of rotation on the back of the timing belt for further reuse.
(3) Loosen the center bolt on the tensioner pulley to remove the timing belt.
Caution: Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated.
If there Is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks.
INSTALLATION SERVICE POINTS
AUTO TENSIONER INSTALLATION
(1) Use a press or vise to compress the push rod of the auto tensioner as slowly as possible. Then align pin hole A of the push rod with pin hole B of the tensioner cylinder.
Caution:
1. Place the auto tensioner at a right angle to the pressing surface of the press or vise.
2. Push in the rod slowly to prevent the push rod from being damaged.
(2) Insert setting pin or wire with a diameter of 1.4 mm (0.06 inches) into the aligned pin holes.
NOTE: The wire should be as stiff as possible (such as piano wire, etc.), and should be bent into the shape of an "L".
(3) Install the auto tensioner to engine.
Caution: Leave the setting pin or wire installed in the auto tensioner.
>B<TIMING BELT INSTALLATION
(1) Align the timing marks of each sprocket.
NOTE: At this time, No. 1 cylinder should be at top dead center on compression stroke.
(2) Use bulldog clips to fix the timing belt in the following procedure to prevent the belt from slacking.
1. Crankshaft sprocket -> 2. Idler pulley -> 3. Front bank side camshaft sprocket -> 4. Water pump pulley -> 5. Rear bank side camshaft sprocket -> 6. Tensioner pulley
Caution: Since the camshaft can turn by the reaction of the valve springs be careful not to get your fingers caught between the sprocket and timing belt.
(3) Apply force counterclockwise to the camshaft sprocket on the rear side. When the tight side of the belt is taut, check that the timing marks are all aligned.
(4) gently raise the tensioner pulley as shown by the arrow, so that the belt does not sag, and temporarily tighten the center bolt.
>C<TIMING BELT TENSION ADJUSTMENT
(1) Turn the crankshaft a 1/4 turn counterclockwise, and then turn it clockwise to the position where the timing marks are aligned.
(2) Loosen the center bolt of the tensioner pulley. Use the special tool and a torque wrench to apply tension to the timing belt as shown in the illustration. Then tighten center bolt to the specified torque.
Caution: When tightening the bolt, make sure that the tensioner pulley shaft doesn't rotate with the bolt.
Specified torque: 4.4 Nm (3.3 ft. lbs.) [tensional torque]
(3) Pull out the auto tensioner setting pin or wire. At this time, check that the setting pin or wire can be pulled out easily. Turn the crankshaft clockwise 2 turns and hold it for 5 minutes or more. Then check again that the auto tensioner setting pin or wire can be pulled or inserted easily.
NOTE: Even if the setting pin or wire cannot be easily inserted,it is satisfactory if the auto tensioner rod projection is within the standard value.
Standard value (A): 3.8 - 4.5 mm (0.149 - 0.177 inches)
If it is not within the standard value, repeat the operations in steps 1. to 3.
(4) Check again that each of the sprocket timing marks is aligned.
>D
Since the engine support bracket mounting bolts differ in size depending on their locations, install them in the numbered sequence shown in the figure.
Caution: When installing the reamer bolt, tighten it slowly while spraying lubricant on the reamer area.
>E
Attach the engine mount bracket so that the arrow mark on the engine mount stopper is in the direction as shown in the illustration.
>F
Caution: Use only the specified special tools, or the pulley damper could be damaged.
INSPECTION
AUTO TENSIONER
- Check the auto tensioner for leaks.
- Check the push rod for cracks.