EM30

ENGINE MECHANICAL Timing Belt (4AFE)

TIMING BELT (4AFE)

COMPONENTS

REMOVAL OF TIMING BELT

1. REMOVE RH FRONT WHEEL
2. REMOVE RH ENGINE UNDER COVER
3. REMOVE WASHER TANK
4. LOOSEN WATER PUMP PULLEY BOLTS AND REMOVE
ALTERNATOR DRIVE BELT
(a) Stretch the belt tight and loosen the water pump
pulley bolts.
(b) Loosen the pivot nut and adjusting bolt, and remove
drive belt.
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ENGINE MECHANICAL Timing Belt (4AFE)

5. (with A/C)
REMOVE A/C COMPRESSOR DRIVE BELT
(a) Loosen the idler pulley mount bolt A.
(b) Loosen the adjusting bolt B and remove the drive belt.

6. (w/ PS)
REMOVE PS PUMP DRIVE BELT
(a) Loosen the pivot and lock bolts.
(b) Swing PS pump toward the engine and remove the
drive belt.

7. DISCONNECT ENGINE WIRE FROM NO.3 TIMING BELT

COVER
(a) Disconnect the following connectors and wire:
Alternator connector
Alternator wire
Oil pressure switch connector
(with A/C)
Compressor connector
(b) Remove the bolt.
(c) Disconnect the wire clamp from the wire bracket, and
disconnect the engine wire from the timing belt
cover.
8. REMOVE SPARK PLUG
(a) Disconnect the hightension cord from spark plug.
(b) Using a plug wrench (16 mm), remove the spark
plugs.

9. REMOVE CYLINDER HEAD COVER

(a) Disconnect the PCV hoses from the cylinder head
cover.
(b) Remove the three cap nuts, grommet and cylinder
head cover with the gasket.
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ENGINE MECHANICAL Timing Belt (4AFE)

10. SET NO.1 CYLINDER AT TDC/COMPRESSION

(a) Turn the crankshaft pulley and align its groove with
the No.1 timing belt cover.
(b) Check that the valve lifters on the No. 1 cylinder are
loose. If not, turn the crankshaft pulley one com-
plete revolution (360
).

11. REMOVE RH ENGINE MOUNTING INSULATOR

(a) Set the jack to the engine.
HINT: Place a wooden block between the jack and
engine.

(b) Remove the three bolts and mounting stay.

(c) Remove the bolt, two nuts, through bolt and RH

mounting.
12. REMOVE WATER PUMP PULLEY

13. REMOVE CRANKSHAFT PULLEY

(a) Using SST to hold the crankshaft pulley, remove the
pulley bolt.
SST 0921314010 and 0933000021
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ENGINE MECHANICAL Timing Belt (4AFE)

(b) Using SST, remove the pulley.

SST 0921331021

14. REMOVE TIMING BELT COVERS

Remove the nine bolts, engine wire bracket and timing belt
covers.
15. REMOVE TIMING BELT GUIDE

16. REMOVE TIMING BELT AND IDLER PULLEY

HINT: If reusing the timing belt, draw a direction arrow on
the belt (in direction of engine revolution), and place match-
marks on the pulleys and belt as shown in the illustration.

(a) Remove the bolt, idler pulley and tension spring.

(b) Remove the timing belt.
17. REMOVE CRANKSHAFT TIMING PULLEY

18. REMOVE CAMSHAFT TIMING PULLEY

Hold the hexagonal head wrench portion of the camshaft
with a wrench, and remove the bolt and timing pulley.
NOTICE: Be careful not to damage the cylinder head with
the wrench.
EM34
ENGINE MECHANICAL Timing Belt (4AFE)

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 mount bolt of the camshaft timing
pulley.
If there are any defects as shown in the illustrations,
check the following points:
(a) Premature splitting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.

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

if either camshaft, water pump is locked.

(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.

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

check the belt guide and the alignment of each
pulley.
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ENGINE MECHANICAL Timing Belt (4AFE)

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

timing cover for damage and check for correct gas-
ket installation and for foreign material on the pulley
teeth.
If necessary, replace the timing belt.

2. INSPECT IDLER PULLEY

Check the turning smoothness of the idler pulley.
If necessary, replace the idler pulley.

3. INSPECT TENSION SPRING

(a) Measure the free length of the tension spring.
Free length: 38.4 mm (1.512 in.)
If the free length is not as specified, replace the tension
spring.
(b) Measure the tension of the tension spring at the speci-
fied installed length.
Installed tension:
3.64.0 kg (7.98.81b,3539Nm)
at 50.2 mm (1.976 in.)
If the tension is not as specified, replace the tension
spring.
EM36
ENGINE MECHANICAL Timing Belt (4AFE)

INSTALLATION OF TIMING BELT

(See page EM30)
1. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin
groove of the pulley, and slide on the pulley.
(b) Temporarily install the timing pulley bolt.
(c) Hold the hexagonal wrench head portion of the cam-
shaft with a wrench, and tighten the timing pulley
bolt.
Torque: 600 kgcm (43 ftIb, 59 Nm)
(d) Turn the hexagonal wrench head portion of the cam-
shaft, and align the hole of the camshaft timing
pulley with the timing mark of the bearing cap.

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 in-
ward.
(c) Using the crankshaft pulley bolt, turn the crankshaft
and align the timing marks of the crankshaft timing
pulley and oil pump body.

3. TEMPORARILY INSTALL IDLER PULLEY AND TENSION

SPRING
(a) Install the idler pulley with the bolt. Do not tighten the
bolt yet.
(b) Install the tension spring.
(c) Push the pulley toward the left as far as it will go and
tighten the bolt.

4. INSTALL TIMING BELT

NOTICE: The engine should be cold.
HINT: If reusing the timing belt, align the points marked
during removal, and install the belt with the arrow pointing
in the direction of engine revolution.
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ENGINE MECHANICAL Timing Belt (4AFE)

5. CHECK VALVE TIMING AND TIMING BELT TENSION

(a) Loosen the timing belt idler pulley mount bolt.

(b) Temporarily install the crank pulley bolt and turn the
crankshaft two revolutions from TDC to TDC.
HINT: Always turn the crankshaft clockwise.

(c) Check the valve timing.

Ensure that each pulley aligns with the marks as
shown in the illustration.

(d) Tighten the timing belt idler pulley mount bolt.

Torque: 375 kgcm (27 ftIb, 37 Nm)
(e) Remove the temporarily installed crank pulley bolt.

(Reference)
(a) Measure the timing belt deflection as shown in the
illustration.
Timing belt deflection: 5 6 mm (0.20 0.24 in.)
at 2 kg (4.4 Ib, 20 N )
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ENGINE MECHANICAL Timing Belt (4AFE)

(b) If the measured value is not within standard, readjust

with the idler pulley.

6. INSTALL TIMING BELT GUIDE

Install the guide, facing the cup side outward.

7. INSTALL TIMING BELT COVERS

(a) Install the timing belt cover with the three bolts.
(b) Install the No.2, No.3 timing belt covers and engine
wire bracket with the six bolts.
Torque: 75 kgcm (^5 inIb, 7.4 Nm)

8. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the
pulley, slide on the pulley.
(b) Temporarily install the pulley bolt.
(c) Using SST, install the pulley bolt.
SST 0921314010 and 0933000021
Torque: 1,200 kgcm (87 ftIb, 118 Nm)

9. TEMPORARILY INSTALL WATER PUMP PULLEY

10. INSTALL RH ENGINE MOUNTING INSULATOR
(a) Install the RH mounting insulator to the engine mounting
bracket with the two nuts and bolt.
Align the RH mounting insulator with the body bracket
and install the mounting through bolt and nut.
Torque: Bolt 650 kgcm (47 ftIb, 64 Nm)
Nut 530 kgcm (38 ftIb, 52 Nm)
Through bolt 890 kgcm (64 ftIb, 87 Nm)
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ENGINE MECHANICAL Timing Belt (4AFE)

(b) Install the RH mounting stay with the three bolts.

Torque: 430 kgcm (31 ftIb, 42 Nm)
(c) Remove the jack.

11. INSTALL CYLINDER HEAD COVER

(a) Apply seal packing as shown in the illustration.
Seal packing: Part No. 0882600080 or equivalent
HINT: Clean the indicated portions by removing the origi-
nal sealant before recoating.

(b) Install the cylinder head cover with the three grommet
and bolts.
(c) Install the PCV hoses.

12. INSTALL SPARK PLUG

(a) Using a plug wrench (16 mm), install the spark plugs.
Torque: 180 kgcm (13 ftIb, 18 Nm)
(b) Connect the hightension cords to spark plugs.

13. CONNECT ENGINE WIRE TO NO.3 TIMING BELT COVER

(a) Connect the engine wire to the timing belt cover, and
connect the wire clamp to the wire bracket.
(b) Install the bolt.
(c) Connect the following connectors and wire:
Alternator connector
Alternator wire
Oil pressure switch connector
(with A/C)
Compressor connector
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ENGINE MECHANICAL Timing Belt (4AFE)

14. TEMPORARILY INSTALL WATER PUMP PULLEY

Install the water pump pulley and partially tighten the four
bolts.
15. (wI PS)
INSTALL PS PUMP DRIVE BELT
16. (with A/C)
INSTALL A/C COMPRESSOR DRIVE BELT
17. INSTALL ALTERNATOR DRIVE BELT
18. ADJUST DRIVE BELTS
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG20 (9550600020) or
Borroughs No. BT3373F
Drive belt tension:
Alternator New belt 160 20 Ib
Used belt 130 20 Ib
PS New belt 125 25 Ib
Used belt 80 20 Ib
A/C New belt 160 20 Ib
Used belt 100 20 Ib
If necessary, adjust the drive belt tension.
HINT:
New belt refers to a belt which has been used less
than 5 minutes on a running engine.
Used belt refers to a belt which has been used on
a running engine for 5 minutes or more.
After installing the drive belt, check that it fits
properly in the ribbed grooves. Check with your
hand to confirm that the belt has not slipped out of
the groove at the bottom of the crank pulley.
After installing a new belt, run the engine for about
5 minutes and then recheck the tension.
19. TIGHTEN WATER PUMP PULLEY BOLTS
20. INSTALL WASHER TANK
21. INSTALL RH ENGINE UNDER COVER
22. INSTALL RH FRONT WHEEL