17

Section 3  Timing Belt Replacement

Figure 37

Air Filter Assembly W/ Hose

High Pressure Cable

Ventilation Pipe

Seal

Cylinder Head

Right Engine Mounting

Fan & Generator V-Belt

V-Belt No.1

Cylinder Head Gasket

Gasket

Timing Chain Or Timing Belt Cover Assembly No. 2

Crankshaft Or Pulley 

Cover Sub-Assembly

Crankshaft Pulley

Timing Belt Guide

Timing Chain Timing Belt 

Cover Sub-Assembly

Generator Assembly

Timing Belt

Fan Pulley

Vane-Type Pump V-Belt V/ Power Steering

18

1. Disconnect engine from all the wire harnesses and cables connected to body.

2. Remove air filter assembly with hose. See (Figure 38)

3. Disconnect oil pipe and water hoses

4. Loose positive and negative cables on battery

5. Detach propeller shaft

6. Loose engine left & right rear brackets after hoisting engine

7. Disconnect all the connectors of engine and the body

8. Remove engine per "Provision 20, Section 2, Chapter 2"

9. Remove A/C compressor to crankshaft pulley V-belt

10. Remove power steering pump V-belt

11. Remove water pump fan pulley

12. Remove high pressure cable.

13. Remove cylinder head cover sub-assembly

14. Remove generator assembly. See (Figure 39)

15. Put the piston in Cylinder 1 to TDC compression position

(a)Turn crankshaft pulley to align its notch to the timing mark "0" 

on the timing belt cover. See (Figure 40).

(b) Check if the "K" mark on camshaft timing pulley and the timing mark

on the bearing cap are aligned. Crank the crankshaft for 360 degrees

if not. See (Figure 41).

16. Remove crankshaft pulley

17. Remove timing belt cover

18. Remove crankshaft gear or pulley cover sub-assembly

19. Remove timing belt cover sub-assembly

Figure 40 

Figure 39

Figure 38

 Figure 41

19

20. Remove timing belt guide wheel

Hint:

(a) Mark on pulley and belt (in engine turning direction) if re-using timing belt (See Figure 42).

(b) Install bolt to the idler pulley. Move pulley to its far left and tighten it temperarily (See Figure 43).

21. Remove spark plug and gasket

Figure 42

22. Install spark plug and gasket

23. Put the piston in Cylinder 1 to TDC compression position.

See (Figure 44)

(a) Turn camshaft hexagon part. Align the mark "K" on the camshaft

timing pulley to the mark on the  bearing cap.

(b) Using the crankshaft pulley bolt, turn the crankshaft, align the mark

on crankshaft timing pulley to the oil pump.

24. Install timing belt. See (Figure 45)

Notice: The engine must be cool.

(a) Install timing belt. Check the tension force between crankshaft timing

pulley and camshaft timing pulley.

Hint: Align the marks if re-using the timing belt when removing. The

engine's rotating direction should be the same with the arrow's when

installing belt.

 (b) Check valve timing. Loose idler bolt.

 (1)   Turn crankshaft from TDC to BDC slowly.

Notice: Crank always in clockwise.

 (2)  Align each pulley to timing mark as shown in the figure. If the timing mark is not aligned,

remove timing belt and reinstall it.

 (3)   Tighten idler bolt.

Torque: 37N. m

 (4) Remove crankshaft pulley bolt.

Figure 44

Figure 45

Figure 43

20

(c) Check timing belt for deflection

Check the belt distorn as shown in the figure.

Belt deflection:

20N: 5~6mm

Re-adjust the idler if the deflection does not comply with the regulation.

25. Install timing belt guide wheel. See (Figure 46)

Install guide, place the cup side outward.

26. Install timing belt cover sub-assembly

Torque: 9.3N. m

27. Install crankshaft gear or pulley cover sub-assembly

Torque: 9.3N. m

28. Install timing belt cover

Torque: 9.3N. m

29. Install crankshaft pulley. See (Figure 47)

(a)  Align pulley lock key and pulley key groove. Install pulley.

(b) Install pulley bolt  Torque: 127N. M

30. Install generator assembly

31. Install water pump pulley

32. Install power steering pump V-belt

33. Install A/C compressor fan to crankshaft pulleyV-belt

34. Install cylinder head cover sub-assembly.

(a) Wipe off all seal packing material.

(b) Apply the seal glue on cylinder head cover as shown in Figure 48.

(c)  Install gasket onto cylinder head cover.

(d) Install cylinder head cover with 4 seal gaskets and 4 nuts.

 Torque: 7.8N. M

(e) Install 2 ventilation hoses onto cylinder head cover.

(f) Install engine wire harness onto cylinder head cover.

(g) Connect generator wire joint.

(h) Connect generator wire.

(i) Connect oil pressure switch connector.

(j)  Install wire clip.

(k) Connect A/C compressor switch connector.

35. Hoist the engine back into the compartment

36. Install left & right rear engine mounting brackets

37. Install ignition coil and high pressure cable

38. Install air filter assembly with hose

Figure 48

Figure 46

Figure 47