1D
Timing Belt and Belt Tensioner Removal and Installation
Reference: Timing Belt and Belt Tensioner Components:K9K
Removal
1) Remove engine assembly from vehicle referring to Engine Assembly Removal and Installation:K9K .
2) Remove injector cover (1) and generator upper bracket (2).
3) Remove timing belt upper cover (1) after unhooking its tabs (2).
4) Remove CMP sensor (3).
5) Remove timing belt lower cover (1) after unhooking its tabs (3) and removing its plastic bolt (2).
6) Remove generator upper bracket support (1) from cylinder head.
7) Remove TDC pin cap (1).
8) Turn crankshaft pulley clockwise, and stop it just before aligning slit (1) of camshaft pulley hub (2) matches with hole (3) of cylinder head.
9) Insert special tool (A) into TDC pin hole as shown in the figure.
Special Tool
(A) : 09919–58110
10) Turn crankshaft pulley clockwise until crankshaft touches special tool (A).
11) Check that special tool (B) inserts holes of camshaft pulley hub and cylinder head smoothly.
Special Tool
(B) : 09919–58120
12) Loosen crankshaft pulley bolt as follows.
a) Lock flywheel using special tool (C).
Special Tool
(C) : 09916–98110
b) Remove special tools (A) and (B).
c) Loosen crankshaft pulley bolt, and remove crankshaft pulley.
d) Remove special tool (C).
e) Insert special tools (A) and (B) to removed positions at Step b).
13) Loosen timing belt tensioner bolt (2).
14) Remove timing belt (1).
15) Remove timing belt tensioner (5), timing belt pulley and timing belt inner cover (4), if necessary.
Installation
Reference: Timing Belt and Belt Tensioner Inspection:K9K
1) Clean mating surface of oil pump pulley, crankshaft timing belt pulley and crankshaft accessory belt pulley.
2) Confirm that special tool (A) and (B) is installed to cylinder block and cylinder head. If special tool(s) is removed, install special tool(s) referring to Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation:K9K or Camshaft and Tappet Removal and Installation:K9K .
Special Tool
(A) : 09919–58110
(B) : 09919–58120
3) Install timing belt inner cover (1), timing belt pulley (2) and timing belt tensioner (3), if necessary.
CAUTION:
Install timing belt pulley so that boss side (6) may come to the gasket holder plate side.
NOTE:
Be sure to position peg (5) of timing belt tensioner (3) to groove (4) of cylinder block precisely.
4) Remove one camshaft pulley bolt (1), and loosen the other two bolts (2) by one turn.
5) Install timing belt (1) with aligning its matching lines (2) with matching marks (3) of camshaft gear ring (4) and injection pump pulley (5).
NOTE:
• Match arrow mark on timing belt with rotating direction of camshaft.
• Timing belt has 18 teeth between its matching lines.
6) Using hexagon wrench (3), align movable index (1) of timing belt tensioner (2) to specified position as shown in the figure by turning timing belt tensioner counterclockwise. And then, tighten timing belt tensioner bolt (4) to specified torque.
Tightening torque
Timing belt tensioner bolt ( a ): 27 N·m ( 2.7 kg-m, 19.5 lb-ft)
7) Check that camshaft pulley bolts (1) do not touch long slotted end (2).
8) Install removed camshaft pulley bolt, and tighten all camshaft pulley bolts to specified torque.
Tightening torque
Camshaft pulley bolt ( a ): 14 N·m ( 1.4 kg-m, 10.5 lb-ft)
9) Remove special tools (A) and (B).
10) Install crankshaft pulley bolt with washer temporarily.
11) Turn crankshaft two revolutions clockwise, and stop it just before aligning slit (1) of camshaft pulley hub (2) matches with hole (3) of cylinder head.
12) Insert special tool (A) into TDC pin hole as shown in the figure.
Special Tool
(A) : 09919–58110
13) Turn crankshaft pulley clockwise until crankshaft touches special tool (A).
14) Check that special tool (B) inserts holes of camshaft belt pulley hub and cylinder head smoothly.
If not, loosen camshaft pulley bolts (1) by one turn, and turn camshaft pulley hub (2) to just aligning slit (3) of camshaft pulley hub with hole (4) of cylinder head.
NOTE:
Do not tighten camshaft pulley bolts.
Special Tool
(B) : 09919–58120
15) Check timing belt pulley key (1) is positioned vertical upwards.
16) Adjust timing belt tension as follows.
a) Loosen timing belt tensioner bolt (1) while holding timing belt tensioner by hexagon wrench, and then gradually bring movable index (3) to center of timing window (2) turning timing belt tensioner.
NOTE:
• If moving index position upper than timing window, turn timing belt tensioner to counterclockwise.
• If moving index position is lower than timing window, turn timing belt tensioner to clockwise.
b) Tighten timing belt tensioner bolt and camshaft pulley bolts as specified torque.
Tightening torque
Timing belt tensioner bolt ( a ): 27 N·m ( 2.7 kg-m, 19.5 lb-ft)
Camshaft pulley bolt : 14 N·m ( 1.4 kg-m, 10.5 lb-ft)
17) Remove special tools (A) and (B).
18) Turn crankshaft two revolutions clockwise, and stop it just before aligning slit (1) of camshaft pulley (2) with hole (3) of cylinder head.
19) Insert special tool (A) into TDC pin hole as shown in figure.
Special Tool
(A) : 09919–58110
20) Turn crankshaft pulley clockwise until crankshaft touches special tool (A).
21) Check that special tool (B) inserts holes of timing belt pulley and cylinder head smoothly.
If not, remove timing belt and return to Step 4).
Special Tool
(B) : 09919–58120
22) Install crankshaft pulley as follows.
a) Lock flywheel using special tool (C).
Special Tool
(C) : 09916–98110
b) Remove crankshaft pulley bolt.
c) Install crankshaft pulley (1) and washer, and tighten new crankshaft pulley bolt (2) as follows.
i) Tighten crankshaft pulley (1) bolt to 120 N·m (12.0 kgf-m, 87.0 lbf-ft).
ii) Retighten crankshaft pulley bolt to 95°.
Tightening torque
Crankshaft pulley bolt ( a ): 120 N·m (12.0 kgf-m, 87.0 lbf-ft) and 95° by the specified procedure
23) Apply sealant “A” to thread of TDC pin cap (1), and tighten TDC pin cap as specified torque.
Tightening torque
TDC pin cap ( a ): 20 N·m ( 2.0 kg-m, 14.5 lb-ft)
“A” : Sealant ( Loctite rhodorseal 5661® )
24) Install generator upper bracket support (1).
Tightening torque
Generator upper bracket support bolt ( a ): 21 N·m ( 2.1 kg-m, 15.5 lb-ft)
25) Install timing belt lower cover (1) hooking its tabs (2), and install its plastic bolt (3).
NOTE:
When installing timing belt lower cover, position its tab (4) into hole (5) of inner timing cover.
26) Install timing belt upper cover (1) hooking its tabs (2).
27) Install CMP sensor (3).
Tightening torque
CMP sensor bolt : 8 N·m ( 0.8 kg-m, 6.0 lb-ft)
28) Install generator upper bracket (1) and injector cover (2).
Tightening torque
Generator upper bracket bolt ( a ): 40 N·m ( 4.0 kg-m, 29.0 lb-ft)
29) Install engine assembly to vehicle referring to Engine Assembly Removal and Installation:K9K .