Timing Belt Removal

REMOVAL OF TIMING BELT





NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

1. Disconnect cable from negative terminal of battery.

CAUTION:
Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.

2. Remove RH front wheel.
3. Remove RH engine under cover.
4. Remove generator.
5. Remove charge air cooler.
6. Remove EGR vacuum modulator and VSV.
7. Remove EGR valve and pipe.
8. Remove throttle body.





9. Remove PS drive belt.
Loosen the two bolts, and remove the drive belt.





10. Slightly jack up engine.
Raise the engine enough to remove the weight from the engine mounting on the right side.





11. Remove RH engine mounting stay.
Remove the bolt, nut and mounting stay.





12. Remove RH engine mounting insulator.
Remove the through bolt, two nuts and mounting insulator.





13. Remove RH engine mounting bracket.
Remove the three bolts and mounting bracket.

HINT: Lower the jack and perform the operation with the engine fully down.

14. Remove cylinder head cover.
15. Remove spark plugs.





16. Remove No.2 timing belt cover.
Remove the five screws, timing belt cover and gasket.
17. Set No.1 cylinder to TDC/Compression.





(a) Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover.

NOTE: Always turn the crankshaft clockwise.





(b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.3 timing belt cover. If not, turn the crankshaft one revolution (360°).

18. Remove timing belt from camshaft timing pulleys.





HINT: (Re-using timing belt)
Place matchmarks on the timing belt and camshaft, timing pulleys, and place a matchmark on the timing belt to match the end of the No.1 timing belt cover.





(When replacing timing belt tensioner only)
To avoid meshing of the timing belt and timing pulley, secure one with a string. And place the matchmarks on the timing belt and RH camshaft timing pulley.





(a) Remove the two bolts and timing belt tensioner.





(b) Remove the timing belt from the camshaft timing pulley.

19. Remove camshaft timing pulleys.





(a) Hold the hexagon wrench head portion of the camshaft with a wrench, and remove the pulley mounting bolts.

HINT: (Intake camshaft timing pulley) Use SST 09249-63010

(b) Remove the camshaft pulleys and pins.

HINT: Arrange the intake and exhaust timing pulleys.

20. Remove crankshaft pulley.





(a) Using SST 09213-54015 (9011 9-08216) and 09330-00021, remove the pulley bolt.





HINT: (When re-using timing belt)
After loosening the crankshaft pulley bolt, check that the timing belt match mark aligns with the end of the No.1 timing belt Cover when the crankshaft pulley groove is aligned with the timing mark "0" of the No.1 timing belt cover. If the matchmark does not align, align as follows:





(When matchmark is out of alignment clockwise)
1. Align the matchmark by pulling the timing belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise.





2. After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley clockwise, and align its groove with timing mark "0" of the No.1 timing belt cover.





(When matchmark is out of alignment counterclockwise)
1. Align the matchmark by pulling the timing belt up on the No.1 idler pulley side while turning the crankshaft pulley clockwise





2. After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley counterclockwise, and align its groove with timing mark "0" of the No.1 timing belt cover.





(b) Using SST 09213-31021, remove the pulley.

HINT: (When re-using timing belt)
Remove the pulley without turning it.





21. Remove No.1 timing belt cover.
Remove the six bolts, timing belt cover and gasket.





22. Remove timing belt guide.





23. Remove timing belt.

HINT: (When re-using timing belt)
Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the timing belt and crankshaft timing pulley.





24. Remove No.1 idler pulley.
Remove the pivot bolt, pulley and plate washer.





25. Remove No.2 idler pulley.
Remove the bolt and pulley.





26. Remove crankshaft timing pulley.
If the pulley cannot be removed by hand, use two screw-drivers.

HINT: Position shop rags as shown to prevent damage.





27. Remove oil pump pulley.
Using SST 09616-30011, remove the nut and pulley.