Section 182 (Timing Belt): Replacement

1. Remove the 5 bolts, the engine moving control rod and the engine mounting stay.

Fig 1: Removing Bolts Engine Moving Control Rod

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1. Remove the bolt and the wire harness bracket.
2. Remove the bolt, the engine mounting stay No. 2 and the engine mounting bracket No. 2.

Fig 2: Removing Engine Mounting Stay RH

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1. Remove the nut and the generator bracket.

Fig 3: Removing Nut

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1. Using SST, loosen the pulley bolt.

   SST 09213-54015 (91651-60855), 09330-00021

   Fig 4: Loosening Pulley Bolt Using SST

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2. Using SST and the pulley bolt, remove the pulley.

   SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

   NOTE: Before using SST, apply lubricating oil on the threads and tip of the center bolt 150.

Fig 5: Removing Pulley Using SST

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1. Disconnect the engine wire protector clamps from the timing belt No. 3 cover.
2. Remove the 5 bolts and the timing belt cover.

Fig 6: Locating Clamp

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1. Remove the 2 bolts, the nut and the engine mounting bracket RH.

Fig 7: Removing Bolts Nut And Engine Mounting Bracket RH

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1. Set No. 1 cylinder to TDC/compression.
   1. Temporarily install the crankshaft pulley bolt and the washer to the crankshaft.
   2. Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley and the oil pump body.
      Fig 8: Identifying Alignment Mark

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   3. Check that timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned.

      If not, turn the crankshaft 1 revolution (360°).

   4. Remove the crankshaft pulley bolt.
   Fig 9: Checking Timing Marks Of Camshaft Timing Pulleys

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2. If re-using the timing belt, check that there are 3 installation marks on the timing belt as shown.
   1. If the installation marks have disappeared, put new installation mark on the timing belt before removing.
   Fig 10: Checking Timing Belt

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3. Set No. 1 cylinder to approx. 60°BTDC/compression.
   1. Turn the crankshaft counterclockwise by approx. 60°.
   NOTE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.
   Fig 11: Turning Crankshaft Counterclockwise By Approx. 60 Degrees

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4. Remove the timing belt tensioner.
   NOTE: Do not install the tensioner as it removed.
5. Remove the timing belt in this order.

Fig 12: Identifying Timing Belt Removing Sequence

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Fig 13: Inspecting Timing Belt

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Check the belt for any defects as shown. Also, check the following.

1. If there is premature parting,
   • Check for proper installation.
   • Check the timing cover gasket for damage and proper installation.
2. If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
3. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump.
4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
5. If there is noticeable wear on the belt teeth,
   • Check timing cover for damage.
   • Check gasket has been installed correctly.
   • Check for foreign object on the pulley teeth.

If there is any doubt about the belt condition, replace the timing belt.

1. Remove any oil or water on the pulleys, and keep them clean.
   NOTE:

   • If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
   • Wipe only the pulleys; do not use any cleaning agent.
2. Inspect the idler pulleys.
   1. Check that the idler pulley turns smoothly.
   2. Visually check the seal portion of the idler pulley for oil leakage.
3. Inspect the water pump.
   1. Turn the pulley, and check that water pump bearing moves smoothly and does not make noise.
   2. Visually check the drain hole for coolant leakage.
4. Temporarily install the crankshaft pulley bolt and the washer to the crankshaft.
5. Turn the crankshaft counterclockwise by approx. 60°.
   NOTE: To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.
   Fig 14: Turning Crankshaft Counterclockwise By Approx 60 Degrees

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6. Using SST, turn the camshaft pulley, and align the timing marks of the timing pulley and the No. 3 timing belt cover.

   SST 09960-10010 (09962-01000, 09963-01000)

   Fig 15: Turning Camshaft Pulley Using SST

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7. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and the oil pump body.
   Fig 16: Aligning Timing Marks Of Crankshaft Timing Pulley

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8. Face the front mark on the timing belt forward.
9. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
10. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
    Fig 17: Identifying Installation Mark

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11. Install the timing belt in this order.

Fig 18: Identifying Timing Belt Installing Sequence

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1. Set the timing belt tensioner upright on the press.
2. Slowly press in the push rod.
   NOTE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.
3. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
4. Release the press.
5. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
   Fig 19: Pressing Push Rod

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   Torque: 27 N.m (280 kgf.cm, 20 ft.lbf) 

   NOTE: Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause failure of its proper operation.
6. Remove the 1.5 mm hexagon wrench from the tensioner.
7. Turn the crankshaft 2 revolutions slowly and align the timing marks of the crankshaft timing pulley and the oil pump body.
   NOTE: Always turn the crankshaft clockwise.
   Fig 20: Turning Crankshaft Revolutions

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8. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown.

   If the marks do not align, remove the timing belt and reinstall it.

9. Remove the crankshaft pulley bolt.

Fig 21: Identifying Timing Mark

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1. Install the timing belt guide, facing the cup side toward the engine front.

Fig 22: Installing Timing Belt Guide

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1. Install the engine mounting bracket RH with the 2 bolts and the nut.

Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

Fig 23: Installing Engine Mounting Bracket RH

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1. Visually check for cracks and breaks in the gasket of the timing belt cover.

   If there is a trace that water is entering at the visual check, replace the timing belt cover.

2. Install the timing belt cover.

   Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

1. Visually check for cracks and breaks in the gasket of the timing belt cover.

   If there is a trace that water is entering at the visual check, replace the timing belt cover.

2. Install the timing belt cover.

   Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

3. Install the engine wire protector cover to the timing belt No. 3 cover.

1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
2. Using SST, install the pulley bolt.

   SST 09213-54015 (91651-60855), 09330-00021

   Torque: 220 N.m (2250 kgf.cm, 162 ft.lbf) 

Fig 24: Installing Pulley Bolt Using SST

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Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

1. Install the engine mounting stay No. 2 and the engine mounting bracket No. 2 with the bolt.

   Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

2. Install the wire harness bracket with the bolt.

   Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) 

Fig 25: Locating Bolt

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1. Install the engine mounting control rod and the engine mounting stay with the 5 bolts. Using several steps, tighten the bolts in the sequence shown.

   Torque: 

   12 mm head 23 N.m (235 kgf.cm, 17 ft.lbf) 

   14 mm head 64 N.m (653 kgf.cm, 47 ft.lbf) 

Fig 26: Identifying Bolt Tightening sequence

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