Timing Belt

Removal & Installation

To Remove:

1. Remove the Generator and Drive Belt.
2. Remove the crankshaft pulley.
3. Remove the rear timing belt front upper cover.
4. Remove the front timing belt front upper cover.
5. Remove the timing belt front lower cover.
6. Remove the engine support bracket.
7. Remove the crank angle sensor.
8. Remove the timing belt by lining up the timing marks then loosening the center bolt on the tension pulley to remove the timing belt.

   NOTE: Put a mark on the back of the timing belt showing the direction of rotation so that if you plan to reuse the belt, you can install it in the same direction.

9. Remove the auto tensioner.
10. Remove the tensioner pulley and tensioner arm.
11. Remove the shaft.
12. Remove the idler pulley and idler pulley adjusting bracket.
13. Remove the adjusting bolt and the adjusting stud.
14. Remove the crankshaft sprocket.
15. Remove the sensing blade.
16. Remove the crankshaft spacer and the crankshaft key.
17. Remove the camshaft sprocket bolt and the camshaft sprocket.
18. Remove the bracket.
19. Remove the timing belt rear cover.

To Install:

1. Install the timing belt rear cover.
2. Install the bracket.
3. Install the camshaft sprocket bolt and the camshaft sprocket.
4. Install the crankshaft key and the crankshaft spacer.
5. Install the sensing blade.
6. Install the crankshaft sprocket.
7. Install the adjusting stud and the adjusting bolt.
8. Install the idler pulley adjusting bracket and the idler pulley.
9. Install the shaft.
10. Install the tensioner arm and tensioner pulley.
11. If the auto tensioner rod is in its fully extended position, reset it as follows:
    • Step 1: Keep the auto tensioner level and in that position, clamp it in the vice with soft jaws.
    • Step 2: Slowly compress the push rod of the auto tensioner until set hole A is aligned with set hole B in the cylinder.
    • Step 3: Insert a wire .055 in (1.4 mm) diameter into the set holes.

      NOTE: The wire should be stiff and should be bent into an "L" shape.

    • Step 4: Unclamp the auto tensioner from the vice.

    CAUTION
    The automatic tensioner must be installed at a right angle to the pressing surface of the vice.

    CAUTION
    To keep the push rod from being damaged, push the rod in slowly.

12. Install the auto tensioner.

    NOTE: Leave the wire installed in the auto tensioner.

13. To install the timing belt, line up the timing marks of the camshaft sprockets and crankshaft sprocket.
14. Install the timing belt by the following procedure so that there is no deflection in the timing belt between each sprocket and pulley:
    • Step 1: Crankshaft sprocket
    • Step 2: Idler pulley
    • Step 3: Camshaft sprocket (left bank)
    • Step 4: Water Pump pulley
    • Step 5: Camshaft sprocket (right bank)
    • Step 6: Tension pulley

    WARNING
    The right bank camshaft sprocket can easily turn because of the spring force applied to it, so use caution when handling so you do not get your fingers caught and injured.

15. Rotate the right bank camshaft sprocket counterclockwise until the tension side of the timing belt is firmly stretched, and then check again that all timing marks are still aligned.

16. Using the special tool (MD998767), push the tension pulley into the timing belt, and then temporarily tighten the center bolt.

17. Using special tool (MD998769), turn the crankshaft 1/4 of a turn counterclockwise and then turn it again clockwise until the timing marks are lined up.
18. Loosen the center bolt on the tensioner pulley. Use special tool (MD998767)and a torque wrench to apply tensioning torque to the timing belt and, at the same time, tighten the center bolt to 36 ft-lb (48 Nm). The timing belt tensioning torque is 3.3 ft-lb (4.4 Nm).

    NOTE: When you tighten the bolt, make sure that the tensioner pulley does not turn along with the bolt.

19. Remove the setting pin that was inserted into the auto tensioner.
20. Turn the crankshaft two turns clockwise to line up the timing marks.
21. Leave everything in this condition for five minutes or more, and then check that the protrusion of the auto tensioner push rod is within the range of the standard value. The standard value (A) is: .189 - .236 in. (4.8 - 6.0mm).

22. If the protrusion is not within the specification, repeat steps (17) to (21).
23. Make sure that the timing marks on all sprockets are properly lined up.
24. Install the crank angle sensor.
25. Install the engine support bracket.
26. Install the timing belt front lower cover.
27. Install the front timing belt front upper cover.
28. Install the rear timing belt front upper cover.
29. Install the crankshaft pulley.
30. Install the Generator and Drive Belt.