Timing Belt: Service and Repair

WARNING: INCORRECT REMOVAL OR INSTALLATION OF THE TIMING BELT CAN RESULT IN DAMAGE TO INTERNAL ENGINE COMPONENTS.






TIMING BELT REPLACEMENT

CAUTION:
- Do not bend or twist timing belt.

- WARNING: AFTER REMOVING TIMING BELT, DO NOT TURN CRANKSHAFT AND CAMSHAFT SEPARATELY BECAUSE VALVES WILL STRIKE PISTON HEADS.

- Make sure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free from oil and water.
- Installation should be carried out when engine is cold.

REMOVAL
1. Remove engine undercover and air duct.
2. Drain engine coolant from radiator.

NOTE: Be careful not to spill coolant on drive belts.

3. Remove radiator.
4. Remove engine cooling fan.
5. Remove the following belts:
- Power steering pump drive belt
- Compressor drive belt
- Alternator drive belt






6. Remove water pump pulley.
7. REMOVE ALL SPARK PLUGS.
8. Remove distributor protector.
9. Remove compressor drive belt idler bracket.
10. Remove fresh-air inlet tube for rocker cover.
11. Remove water inlet hose for thermostat housing.
12. Remove crankshaft pulley bolt.
13. Remove crankshaft pulley with a suitable puller.
14. Remove front upper and lower belt covers.






15. WARNING: DISCONNECT NEGATIVE BATTERY CABLE. Set No. 1 piston at T.D.C. on its compression stroke by rotating crankshaft. test for compression coming on only with old belt installed and undisturbed. If timing belt is broken, check for engine damage.






CONFIRM THAT DISTRIBUTOR ROTOR HEAD IS SET AS SHOWN IN FIGURE. (DISTRIBUTOR UNDISTURBED)

Align punchmark on L.H. camshaft sprocket with punchmark on timing belt upper rear cover. Align punchmark on crankshaft sprocket with notch on oil pump housing. TEMPORARILY INSTALL CRANK PULLEY BOLT ON CRANKSHAFT SO THAT CRANKSHAFT CAN BE ROTATED ONLY WITH TIMING BELT PROPERLY INSTALLED.

- WARNING: AFTER REMOVING TIMING BELT, DO NOT TURN CRANKSHAFT AND CAMSHAFT SEPARATELY BECAUSE VALVES WILL STRIKE PISTON HEADS.






16. Loosen timing belt tensioner nut, turn tensioner, then remove timing belt.

- WARNING: AFTER REMOVING TIMING BELT, DO NOT TURN CRANKSHAFT AND CAMSHAFT SEPARATELY BECAUSE VALVES WILL STRIKE PISTON HEADS.

INSPECTION






1. Visually check the condition of timing belt. Replace if any abnormality is found.






2. Check belt tensioner for smooth turning.
3. Check condition of tensioner spring.

INSTALLATION

WARNING: AFTER REMOVING TIMING BELT, DO NOT TURN CRANKSHAFT AND CAMSHAFT SEPARATELY BECAUSE VALVES WILL STRIKE PISTON HEADS.






1. CONFIRM THAT NO.1 PISTON IS SET AT T.D.C. ON ITS COMPRESSION STROKE. WARNING: DO NOT CHECK FOR COMPRESSION BY TURNING THE CRANKSHAFT WITH BELT REMOVED.






2. Install tensioner and tensioner spring.

NOTE: If stud is once removed, apply locking sealant to threads before installing.






3. Turn tensioner fully outward with hexagon wrench, and temporarily tighten lock nut.











4. Set timing belt.
(1) Align white lines on timing belt with punchmarks on camshaft sprockets and crankshaft sprocket.
(2) Point arrow on timing belt toward front belt cover.






5. Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench.
6. Turn tensioner 70 to 80 degrees clockwise with hexagon wrench, and temporarily tighten lock nut.
7. TURN CRANKSHAFT CLOCKWISE AT LEAST 2 TIMES WITH BELT INSTALLED, THEN SLOWLY SET NO.1 PISTON AT T.D.C. ON ITS COMPRESSION STROKE.






8. Push middle of timing belt between R.H. camshaft sprocket and tensioner pulley with force of 98 Nm (10 kg, 22 lb).
9. Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench.






10. Set clearance gauge as shown in figure which is 0.35 mm (0.0138 in) thick and 12.7 mm (0.500 in) wide.






11. Turn crankshaft clockwise, and set clearance gauge as shown in figure. Timing belt will move about 2.5 teeth.
12. Tighten tensioner lock nut, keeping tensioner steady with hexagon wrench.
13. Turn crankshaft clockwise or counterclockwise, and remove clearance gauge.
14. TURN CRANKSHAFT CLOCKWISE AT LEAST 2 TIMES WITH BELT INSTALLED, THEN SLOWLY SET NO.1 PISTON AT T.D.C. ON ITS COMPRESSION STROKE.






15. Measure deflection of timing belt midway between cam shaft pulleys when pushing with 10 kg force.
Belt deflection (Reference value): 13 - 15 mm (0.51-0.59 in) 98 Nm (10 kg, 22 lb)







16. Install lower and upper belt covers.
17. During installation of crankshaft pulley, locate TDC mark on pulley and confirm it aligns with timing pointer, with #1 piston at top dead center.
18. Reconnect battery.