2-3 [W3A1] SERVICE PROCEDURE
3. Timing Belt
3. Timing Belt 6) Remove front belt cover.
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT
COVER
1) Remove A/C belt. (With A/C model)
B2M2587A
2. TIMING BELT
1) Remove timing belt guide. (MT vehicles only)
B2M2584
2) Remove A/C belt tensioner. (With A/C model)
S2M0294
B2M2585
3) Remove crankshaft pulley bolt. To lock
crankshaft, use ST.
ST 499977100
CRANKSHAFT PULLEY WRENCH
H2M2393C
4) Remove crankshaft pulley.
5) Remove belt cover (LH).
14
SERVICE PROCEDURE [W3A2] 2-3
3. Timing Belt
2) If alignment mark (a) and/or arrow mark (which (2) Using white paint, put alignment and/or
indicates rotation direction) on timing belt fade arrow marks on timing belts in relation to the
away, put new marks before removing timing belt crank sprocket and cam sprockets.
as shown in procedures below.
(1) Turn crankshaft using ST. Align mark (a) of
sprocket to cylinder block notch (b) and ensure
that right side cam sprocket mark (c), cam cap
and cylinder head matching surface (d) and/or
left side cam sprocket mark (e) and belt cover
notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET
B2M2591
Specified data:
Z1: 44 tooth length
Z2: 40.5 tooth
B2M2590A
B2M3434A
3) Remove belt idler (No. 2).
4) Remove belt idler No. 2.
S2M1008
5) Remove timing belt.
B2M3430A
B2M3435
15
2-3 [W3A3] SERVICE PROCEDURE
3. Timing Belt
3. BELT IDLER AND AUTOMATIC BELT 2) Remove crankshaft sprocket.
TENSION ADJUSTER ASSEMBLY
1) Remove belt idler (No. 1).
B2M2600C
B2M2596
2) Remove automatic belt tension adjuster assem-
bly.
S2M0414C
3) Remove belt cover No. 2 (LH).
4) Remove belt cover No. 2 (RH).
CAUTION:
H2M2375
Do not damage or lose the seal rubber when
removing belt covers.
4. CAMSHAFT AND CRANKSHAFT
SPROCKET
1) Remove camshaft sprocket No. 1 and No. 2. To
lock camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
B2M2601
5) Remove tensioner bracket.
H2M2377A
H2M2380
16
SERVICE PROCEDURE [W3B5] 2-3
3. Timing Belt
B: INSPECTION I Press-in the push adjuster rod gradually tak-
ing more than three minutes.
1. TIMING BELT I Do not allow press pressure to exceed 9,807
1) Check timing belt teeth for breaks, cracks, and N (1,000 kg, 2,205 lb).
wear. If any fault is found, replace belt. I Press the adjuster rod as far as the end sur-
2) Check the condition of back side of belt; if any face of the cylinder. Do not press the adjuster
crack is found, replace belt. rod into the cylinder. Doing so may damage the
cylinder.
CAUTION:
I Be careful not to let oil, grease or coolant 4) Measure the extension of rod beyond the body.
contact the belt. Remove quickly and thor- If it is not within specifications, replace with a new
oughly if this happens. one.
I Do not bend the belt sharply. Rod extension: H
Bending radius: h 5.7±0.5 mm (0.224±0.020 in)
60 mm (2.36 in) or more
H2M2381A
G2M0115
3. BELT TENSION PULLEY
2. AUTOMATIC BELT TENSION 1) Check mating surfaces of timing belt and con-
ADJUSTER tact point of adjuster rod for abnormal wear or
1) Visually check oil seals for leaks, and rod ends scratches. Replace automatic belt tension adjuster
for abnormal wear or scratches. If necessary, assembly if faulty.
replace faulty parts. 2) Check tension pulley for smooth rotation.
CAUTION: Replace if noise or excessive play is noted.
Slight traces of oil at rod’s oil seal does not 3) Check tension pulley for grease leakage.
indicate a problem.
4. BELT IDLER
2) Check that the adjuster rod does not move
1) Check belt idler for smooth rotation. Replace if
when a pressure of 294 N (30 kg, 66 lb) is applied
to it. This is to check adjuster rod stiffness. noise or excessive play is noted.
3) If the adjuster rod is not stiff and moves freely 2) Check belt outer contacting surfaces of idler
when applying 294 N (30 kg, 66 lb), check it using pulley for abnormal wear and scratches.
the following procedures: 3) Check belt idler for grease leakage.
(1) Slowly press the adjuster rod down to the
5. CAMSHAFT AND CRANKSHAFT
end surface of the cylinder. Repeat this motion
2 or 3 times. SPROCKET
(2) With the adjuster rod moved all the way up, 1) Check sprocket teeth for abnormal wear and
apply a pressure of 294 N (30 kg, 66 lb) to it. scratches.
Check adjuster rod stiffness. 2) Make sure there is no free play between
(3) If the adjuster rod is not stiff and moves sprocket and key.
down, replace the automatic belt tension 3) Check crankshaft sprocket notch for sensor for
adjuster assembly with a new one. damage and contamination of foreign matter.
CAUTION:
I Always use a vertical type pressing tool to
move the adjuster rod down.
I Do not use a lateral type vise.
I Push adjuster rod vertically.
17
2-3 [W3C1] SERVICE PROCEDURE
3. Timing Belt
C: INSTALLATION 4) Install crankshaft sprocket.
1. CAMSHAFT AND CRANKSHAFT
SPROCKET
1) Install tensioner bracket.
Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
B2M2600C
H2M2380
2) Install belt cover No. 2 (RH).
Tightening torque:
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb)
S2M0414C
3) Install belt cover No. 2 (LH).
Tightening torque: 5) Install camshaft sprocket No. 1 and No. 2. To
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb) lock camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
Tightening torque:
78±5 N·m (8.0±0.5 kg-m, 57.9±3.6 ft-lb)
CAUTION:
Do not confuse left and right side camshaft
sprockets during installation. The camshaft
sprocket No. 2 is identified by a projection
used to monitor camshaft position sensor.
B2M2601
H2M2377A
2. AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt
tension adjuster assembly;
CAUTION:
I Always use a vertical type pressing tool to
move the adjuster rod down.
18
SERVICE PROCEDURE [W3C3] 2-3
3. Timing Belt
I Do not use a lateral type vise. 2) Install automatic belt tension adjuster assem-
I Push adjuster rod vertically. bly.
I Be sure to slowly move the adjuster rod Tightening torque:
down applying a pressure of 294 N (30 kg, 66 39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)
lb).
I Press-in the push adjuster rod gradually tak-
ing more than three minutes.
I Do not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
I Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
I Do not release press pressure until stopper
pin is completely inserted. H2M2384
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool. 3) Install belt idler (No. 1).
(2) Slowly move the adjuster rod down with a Tightening torque:
pressure of 294 N (30 kg, 66 lb) until the 39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)
adjuster rod is aligned with the stopper pin hole
in the cylinder.
B2M2596
H2M2382
3. TIMING BELT
(3) With a 2 mm (0.08 in) dia. stopper pin or a 1) Installation of timing belt
2 mm (0.08 in) (nominal) dia. hex bar wrench (1) Turn camshaft sprocket No. 2 using ST1,
inserted into the stopper pin hole in the cylinder, and turn camshaft sprocket No. 1 using ST2 so
secure the adjuster rod. that their alignment marks come to top posi-
tions.
ST1 499207100 CAMSHAFT SPROCKET
WRENCH
ST2 499207400 CAMSHAFT SPROCKET
WRENCH
H2M2383A
B2M3436A
19
2-3 [W3C3] SERVICE PROCEDURE
3. Timing Belt
(2) While aligning alignment mark on timing 5) Install timing belt guide. (MT vehicles only)
belt with marks on sprockets, position timing (1) Temporarily tighten remaining bolts.
belt properly.
CAUTION:
Ensure belt’s rotating direction is correct.
S2M0294
(2) Check and adjust clearance between timing
belt and timing belt guide by using thickness
B2M3437A gauge.
2) Install belt idler No. 2. Clearance:
Tightening torque: 1.0±0.5 mm (0.039±0.020 in)
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)
3) Install belt idler (No. 2).
Tightening torque:
39±4 N·m (4.0±0.4 kg-m, 28.9±2.9 ft-lb)
S2M0297
(3) Tighten remaining bolts.
Tightening torque:
9.8±1.0 N·m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
S2M1008
4) After ensuring that the marks on timing belt and
camshaft sprockets are aligned, remove stopper
pin from belt tensioner adjuster.
CAUTION:
After properly installing timing belt, remove
rocker cover and ensure that the valve lash
adjuster contains no air.
H2M2415
H2M2387A
20
SERVICE PROCEDURE [W3C4] 2-3
3. Timing Belt
4. CRANKSHAFT PULLEY AND BELT (3) Tighten the bolts temporarily with tightening
COVER torque of 44 N·m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
1) Install front belt cover. them in an angle between 65 degrees and 75
Tightening torque: degrees.
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb) CAUTION:
2) Install belt cover (LH). Conduct the tightening procedures by confirm-
Tightening torque: ing the turning angle of the crankshaft pulley
5±1 N·m (0.5±0.1 kg-m, 3.6±0.7 ft-lb) bolt referring to the gauge indicated on the belt
cover.
6) Install A/C belt tensioner. (With A/C model)
B2M2587A
3) Install crankshaft pulley. B2M2585
4) Install pulley bolt.
To lock crankshaft, use ST. 7) Install A/C belt. (With A/C model)
ST 499977100 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N·m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
177±5 N·m (18.0±0.5 kg-m, 130.2±3.6 ft-lb) B2M2584
H2M2393A
5) Confirm that the tightening angle of the crank-
shaft pulley bolt is 65 degrees or more. If not, con-
duct the following procedures (1) through (4).
(1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
21
