Timing Belt

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS
[A] TIMING BELT REMOVAL

CAUTION: Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. These parts should not be washed or immersed in solvent. Replace parts if contaminated.
If there is oil or water on any part, check the front case oil seal, camshaft oil seal, and water pump for leaks.





1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove the timing belt.

[B] CAMSHAFT SPROCKET REMOVAL





1. While holding the camshaft sprocket with special tools MB990767 and MD998715, loosen the camshaft sprocket bolt.
2. Remove the camshaft sprocket.

INSTALLATION SERVICE POINTS
]A[ CAMSHAFT SPROCKET INSTALLATION





1. Fit the camshaft sprocket to the front end of the camshaft.
2. While holding the camshaft sprocket with special tools MB990767 and MD998715, tighten the camshaft sprocket bolt.
Tightening torque: 88 Nm (65 ft. lbs.)

]B[ AUTO-TENSIONER INSTALLATION
If the auto-tensioner rod is fully extended, reset it as follows:





1. Clamp the auto-tensioner in the vise with soft jaws.
2. Push in the rod little by little with the vise until the set hole A in the rod is aligned with the hole B in the cylinder.
3. Insert a wire [1.4 mm (0.055 inches) in diameter] into the set holes. This auto-tensioner setting wire will be used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.

]C[ TIMING BELT INSTALLATION

CAUTION: Do not turn the camshaft when the piston in No.1 cylinder is at the top dead center on the compression stroke. Doing so can cause the lifted valve to hit against the piston, resulting in damaging parts.





1. Turn the crankshaft sprocket to position its timing mark 3 teeth away from the timing mark on the crankcase.





2. Align the timing marks for the left bank camshaft sprocket.
3. Align the timing marks for the right bank camshaft sprocket.





4. Align the timing marks of the crankshaft sprocket.
5. Install the timing belt on each sprocket and pulley in the following sequence. Do not leave the belt slack between each sprocket and pulley.
1) Crankshaft sprocket
2) Idler pulley
3) Left bank camshaft sprocket
4) Water pump pulley
5) Right bank camshaft sprocket
6) Tensioner pulley





6. Install special tool MD998767 to the tensioner pulley.
While pushing the pulley lightly against the belt using the special tool, tighten the flange bolt.
Tightening torque: 48 Nm (35 ft. lbs.)





7. Check to see that the timing marks of all the sprockets are in a alignment.





8. After mounting the special tool MD998769, tighten the crankshaft bolt. And then rotate the crankshaft a quarter turn counterclockwise. Then rotate it back clockwise to verify that all the timing marks are in alignment.





9. Loosen the flange bolt securing the tensioner pulley, and then mount special tool MD998767 and a torque wrench on the tensioner pulley.
10. Torque it to 4.4 Nm (39 inch lbs.) with the torque wrench.
11. While holding the tensioner pulley in position, tighten the flange bolt to the specified torque.
Tightening torque: 48 Nm (35 ft. lbs.)
12. Rotate the crankshaft two turns clockwise and leave it alone for approximately five minutes.





13. Check to see whether the metal wire inserted when the auto-tensioner was installed can be removed without any resistance.
If the metal wire can be removed without any resistance, it means that the belt has a proper tension. Therefore, remove the metal wire. In this condition, check that the projection of the rod of the auto-tensioner is within the standard value.
Standard value: 3.8 - 5.0 mm (0.15 - 0.20 inch)
14. If the metal wire offers resistance when removed, repeat the previous steps 9 through 12 until a proper belt tension is obtained.

]D[ ENGINE SUPPORT BRACKET, RIGHT INSTALLATION





The mounting bolts of the right engine support bracket must be tightened in the order shown in the illustration.
Tightening torque: 44 Nm (33 ft. lbs.)
Bolt length
85 mm -- Bolt 3
95 mm -- Other bolts

INSPECTION

TIMING BELT
Replace the belt if any of the following conditions exist.





1. Hardening of rubber backing-back side is glossy without resilience and leaves no indent when pressed with fingernail.





2. Cracks on rubber back
3. Cracks or peeling of canvas
4. Cracks on tooth bottom
5. Cracks on belt





6. Abnormal wear of belt sides. Normal wear is indicated if the sides are sharp as if cut by a knife. Abnormal wear is indicated if the sides are ragged.





7. Abnormal wear on teeth
8. Tooth missing and canvas fiber exposed.

TENSIONER





Turn the pulley. If it does not rotate smoothly, or develops noise or excessive play, replace the timing belt tensioner.

AUTO-TENSIONER
1. Check for oil leaks. If oil leaks are evident, replace the auto-tensioner.
2. Check the rod end for wear or damage and replace the auto-tensioner if necessary.





3. Measure the rod projection length. If the reading is not within the standard value, replace the auto-tensioner.
Standard value: 12 mm (0.5 inch)





4. Press the rod with a force of 98 to 196 N (22 to 44 pounds) and measure the movement of the rod. If the measured value is outside the standard value, replace the auto-tensioner.
Standard value: 1.0 mm (0.03 inch) or less