4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 7

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 counterclockwise)

•

Align the matchmark by pulling the timing belt up
on the No.1 idler pulley side while turning the
crankshaft pulley clockwise.

•

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 clockwise)

•

Align the matchmark by pulling the timing belt up
on the water pump pulley side while turning the
crankshaft pulley counterclockwise.

•

After aligning the matchmark, hold the timing
belt. And turn the crankshaft pulley counterclock-
wise, and align its groove with timing mark ”0” of
the N o–1 timing belt cover.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–50

23. REMOVE TIMING BELT

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

(b) Using SST, remove the pulley.

SST 09213–31021

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.

24. REMOVE NO.1 IDLER PULLEY

Remove the pivot bolt, pulley and plate washer.

22. REMOVE TIMING BELT GUIDE

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–51

26. REMOVE CRANKSHAFT TIMING PULLEY

If the pulley cannot be removed by hand, use two
screwdrivers.
HINT: Position shop rags as shown to prevent damage.

27. REMOVE OIL PUMP PULLEY

Using SST, remove the nut and pulley.
SST 09616–30011

25. REMOVE NO.2 IDLER PULLEY

Remove the bolt and pulley.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–52

INSPECTION OF TIMING BELT
COMPONENTS

1. INSPECT 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.

If there are any defects as shown in the illustrations,
check the following points:
(a) Premature parting

•

Check for proper installation.

•

Check the timing cover gasket for damage and
proper installation.

(d) If there is wear or damage on only one side of the

belt, check the belt guide and the alignment of each
pulley.

(c) 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.

(b) If the belt teeth are cracked or damaged, check to

see if either the camshaft or water pump is locked.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–53

3. INSPECT TIMING BELT TENSIONER

(a) Visually check tensioner for oil leakage.
HINT: If there is only a small trace of oil on the seal of
the push rod, the tensioner is all right.
If leakage is found, replace the tensioner.

(c) Measure the protrusion of the push rod from the

housing end.

Protrusion: 8.5 – 9.5 mm (0.335 – 0.374 in.)

If the protrusion is not as specified, replace the tensioner.

(e) If there is noticeable wear on the belt teeth, check

the timing cover for damage, correct gasket installa-
tion and the foreign material on the pulley teeth.
If necessary, replace the timing belt.

(b) Hold the tensioner with both hands, and push the

push rod strongly against the floor or wall to check
that it doesn’t move.

If the push rod moves, replace the tensioner.

2. INSPECT IDLER PULLEYS

Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–54

INSTALLATION OF TIMING BELT

(See page 

EM–46

)

1. INSTALL OIL PUMP PULLEY

(a) Align the cutouts of the pulley and shaft, and slide

the pulley.

(b) Using SST, install the nut.

SST 09616–30011

Torque: 35 N–m (355 kgf–cm, 26 ft–lbf)

4. INSTALL NO.1 IDLER PULLEY

(a) Apply adhesive to two or three threads of the pivot

bolt.

Adhesive: Part No. 08833–00080, THREE BOND 1344,

LOCTITE 242 or equivalent

(b) Install the plate washer and pulley with the pivot

bolt.

Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)

(c) Check that the pulley bracket moves smoothly.

5. TEMPORARILY INSTALL TIMING BELT

NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft

and face the key groove of the crankshaft
timing pulley upward.

2. INSTALL CRANKSHAFT TIMING PULLEY

(a) Align the pulley set key with the key groove of the

pulley.

(b) Slide on the timing pulley facing the flange side

inward.

3. INSTALL NO.2 IDLER PULLEY

(a) Install the pulley with the bolt.
Torque: 43 N–m (440 kgf–cm, 32 ft–lbf)

(b) Check that the idler pulley moves smoothly.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

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(b) Remove any oil or water on the crankshaft pulley, oil

pump pulley, water pump pulley, No.1 idler pulley
and No.2 idler pulley, and keep them clean.

(c) Install the timing belt on the crankshaft timing pulley, oil

pump pulley, No.2 idler pulley, water pump
pulley and No.1 idler pulley.

HINT (when re–using timing belt) : Align the matchmarks
of the crankshaft timing pulley and timing belt, and
install the belt with the arrow pointing in the direction of
engine revolution.

6. INSTALL TIMING BELT GUIDE

Install the guide, facing the cup side outward.

8. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the

pulley, and slide on the pulley.

(b) Using SST, install and torque the bolt.

SST 09213–54015 (90119–08216) and 09330–00021

Torque: 108 N–m (1,100 kgf–cm, 80 ft–lbf)

9. INSTALL CAMSHAFT TIMING PULLEYS

(a) Using a wrench, turn and align the groove of the

camshaft with the drilled mark of the No.1 camshaft
bearing cap.

7. INSTALL NO.1 TIMING BELT COVER

(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the six bolts.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

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(d) Hold the hexagon wrench head portion of the

camshaft with a wrench, and tighten the bolts.

Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)

41 N–m (420 kgf–cm, 30 ft–lbf)

HINT (intake. camshaft timing pulley):

•

Use SST.
SST 09249–63010

•

Use a torque wrench with a fulcrum length of 340 mm
(13.39 in.).

11. INSTALL TIMING BELT

HINT (When re–using timing belt):

•

Check that the matchmark on the timing belt matches
the end of the No.1 timing belt cover.

If the matchmark does not align, shift the meshing of the
timing belt and crankshaft timing pulley until they align.
(See page 

EM–50

)

(b) Slide the timing pulley onto the camshaft, facing

mark ”S” upward.

(c) Align the pin holes of the camshaft and timing pulley, and

insert the knock pin.

10. 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.

(b) Turn the camshaft, and align the timing marks of the

camshaft timing pulleys and No.3 timing belt cover.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–57