Timing belt (3S-GTE)¶

Components¶

Removal of timing belt¶

Disconnect cable from negative terminal of battery.

Caution

Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.
Remove engine under covers.
Remove RH engine hood side panel.
Remove suspension upper brace. (See Cylinder block (3S-GTE) › Removal of engine, step 8)
Remove cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (3S-GTE) › Removal of engine, step 13)
Remove intercooler. (See Intercooler, steps 4, 5, 7–13)
Remove RH front wheel.
Remove alternator drive belt.
1. Loosen the pivot and adjusting lock bolts.
2. Loosen the adjusting bolt, and remove the drive belt.
Slightly jack up engine.

Raise the engine enough to remove the weight from the engine mounting on the right side.
Remove RH engine mounting stay.

Remove the two bolts, nut and mounting stay.
Remove RH engine mounting insulator.

Remove the through bolt, two nuts and mounting insulator.
Remove RH engine mounting bracket.

Remove the three bolts and mounting bracket.

Hint

Lower the jack and perform the operation with the engine fully up.
Remove EGR vacuum modulator and VSV. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 22)
Remove throttle body. (See steps 5 to 8, 10 and 11 on pages FI-135 and 136)
Remove hose clamp and VTV clamp of air by-pass valve. (See Turbocharger › Removal of turbocharger, steps 15, 16)
Remove cylinder head cover. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 35)
Remove spark plugs. (See On-vehicle inspection (3S-GTE) › Inspection of spark plugs)
Remove No.2 timing belt cover.

Remove the five screws, timing belt cover and gasket.
Set No.1 cylinder to TDC/compression.
1. Turn the crankshaft pulley and align its groove with timing mark "O" of the No.1 timing belt cover.
  
  Notice
  
  Always turn the crankshaft clockwise.
2. Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.3 timing belt cover.
  
  If not, turn the crankshaft one revolution (360°).
Remove timing belt from camshaft timing pulleys.
Hint
- (Re-using timing belt)
  
  Place matchmarks on the timing belt and camshaft timing pulleys, and place a matchmark on the timing belt to match the end of the No.1 timing belt cover.
Hint
- (When replacing timing belt tensioner only)
  
  To avoid meshing of the timing belt and timing pulley, secure one with a string. And place the matchmarks on the timing belt and RH camshaft timing pulley.
1. Remove the two bolts and timing belt tensioner.
2. Remove the timing belt from the camshaft timing pulley.
Remove camshaft timing pulleys.
1. Hold the hexagonal wrench head portion of the camshaft with a wrench, and remove the pulley mount bolts.
  
  Hint (intake camshaft timing pulley)
  
  Use SST.
  
  SST 09249-63010
2. Remove the camshaft pulleys and pins.
  
  Hint
  
  Arrange the intake and exhaust timing pulleys.
Remove crankshaft pulley.
1. Using SST, remove the pulley bolt.
  
  SST 09213-54015 (90119-08216) and 09330-00021
  Hint (when re-using timing belt)
  
  After loosening the crankshaft pulley bolt, check that the timing belt matchmark aligns with the end of the No.1 timing belt cover when the crankshaft pulley groove is aligned with the timing mark "O" of the No.1 timing belt cover. If the matchmark does not align, align as follows.
  
  (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 clockwise, and align its groove with timing mark "0" of the No.1 timing belt cover.
  (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 counterclockwise, and align its groove with timing mark "0" of the No.1 timing belt cover.
2. Using SST, remove the pulley.
  
  SST 09213-31021
  
  Hint (when re-using timing belt)
  
  Remove the pulley without turning it.
Remove No.1 timing belt cover.

Remove the six bolts, timing belt cover and gasket.
Remove timing belt guide.
Remove timing belt.

Hint (when re-using timing belt)

Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the timing belt and crankshaft timing pulley.
Remove No.1 idler pulley.

Remove the pivot bolt, pulley and plate washer.
Remove No.2 idler pulley.

Remove the bolt and pulley.
Remove crankshaft timing pulley.

If the pulley cannot be removed by hand, use two screwdrivers.

Hint

Position shop rags as shown to prevent damage.
Remove oil pump pulley.

Using SST, remove the nut and pulley.

SST 09616-30011

Inspection of timing belt components¶

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:
1. Premature parting
  - Check for proper installation.
  - Check the timing cover gasket for damage and proper installation.
2. If the belt teeth are cracked or damaged, check to see if either the camshaft or water pump is locked.
3. 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.
4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
5. If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation and foreign material on the pulley teeth.
  
  If necessary, replace the timing belt.
Inspect idler pulleys.

Check the turning smoothness of the idler pulley.

If necessary, replace the idler pulley.
Inspect timing belt tensioner.
1. 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.
2. 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.
3. 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.

Installation of timing belt¶

(See Components)

Install oil pump pulley.
1. Align the cutouts of the pulley and shaft, and slide the pulley.
2. Using SST, install the nut.
SST 09616-30011

Torque: 355 kg-cm (26 ft-lb, 35 N·m)
Install crankshaft timing pulley.
1. Align the pulley set key with the key groove of the pulley.
2. Slide on the timing pulley facing the flange side inward.
Install No.2 idler pulley.
1. Install the pulley with the bolt.
  
  Torque: 440 kg-cm (32 ft-lb, 43 N·m)
2. Check that the idler pulley moves smoothly.
Install No.1 idler pulley.
1. Apply adhesive to two or three threads of the pivot bolt.
  
  Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
2. Install the plate washer and pulley with the pivot bolt.
  
  Torque: 440 kg-cm (32 ft-lb, 43 N·m)
3. Check that the pulley bracket moves smoothly.
Temporarily install timing belt.

Notice

The engine should be cold.
1. Using the crankshaft pulley bolt, turn the crankshaft and position the key groove of the crankshaft timing pulley upward.
2. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley, No.2 idler pulley, and keep them clean.
3. 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 camshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution.
Install timing belt guide.

Install the guide, facing the cup side outward.
Install No.1 timing belt cover.
1. Install the gasket to the timing belt cover.
2. Install the timing belt cover with the six bolts.
Install crankshaft pulley.
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install and torque the bolt.
  
  SST 09213-54015 (90119-08216) and 09330-00021
  
  Torque: 1,100 kg-cm (80 ft-lb, 108 N·m)
Install camshaft timing pulleys.
1. Using a wrench, turn and align the groove of the camshaft with the drilled mark of the No.1 camshaft bearing cap.
2. Slide the timing pulley onto the camshaft, facing mark "S" upward.
3. Align the pin holes of the camshaft and timing pulley, insert the knock pin.
4. Hold the hexagonal wrench head portion of the camshaft with a wrench, and tighten the bolts.
  
  Torque:
  - 600 kg-cm (43 ft-lb, 59 N·m)
  - 420 kg-cm (30 ft-lb, 41 N·m) for SST
  Hint (intake camshaft timing pulley)
  - Use SST.
    
    SST 09249-63010
  - Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).
Set No.1 cylinder to TDC/compression.
1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
2. Turn the camshaft, and align the timing marks of the camshaft timing pulleys and No.3 timing belt cover.
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 Idle and/or 2,500 rpm HC/CO concentration check method)
Hint (when re-using timing belt)
- Align the matchmarks of the timing belt and camshaft timing pulleys.
1. Remove any oil or water on the camshaft timing pulley, and keep it clean.
2. Install the timing belt, insure that there is tension between the crankshaft timing pulley and intake camshaft timing pulley.
Set timing belt tensioner.
1. Using a press, slowly press in the push rod using 100 – 1,000 kg (220 – 2,205 lb, 981 – 9,807 N) of pressure.
2. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
3. Release the press.
Install timing belt tensioner.
1. Turn the No.1 idler pulley bolt counterclockwise obtain the specified torque toward the left as far as No.1 idler pulley will go, and temporarily install the tensioner with the two bolts.
2. Slowly turn the crankshaft pulley ⅚ revolution, and align its groove with the ATDC 60° mark of the No.1 timing belt cover.
  
  Notice
  
  Always turn the crankshaft clockwise.
3. Insert a 1.90 mm (0.075 in.) feeler gauge between the tensioner body and No.1 idler pulley stopper.
4. Turn the No.1 idler pulley bolt counterclockwise to obtain the specified torque.
  
  Torque: 180 kg-cm (13 ft-lb, 18 N·m)
  
  Notice
  
  To apply the correct torque, apply the torque wrench along the axis through the bolts of the No.1 idler pulley and exhaust camshaft timing pulley.
5. While pushing the tensioner, alternately tighten the two bolts.
  
  Torque: 210 kg-cm (15 ft-lb, 21 N·m)
6. Remove the 1.27 mm hexagon wrench from the tensioner.
7. Slowly turn the crankshaft pulley one revolution, and align its groove with the ATDC 60° mark of the No.1 timing belt cover.
  
  Notice
  
  Always turn the crankshaft clockwise.
8. Turn the No.1 idler pulley bolt counterclockwise to obtain the specified torque.
  
  Torque: 180 kg-cm (13 ft-lb, 18 N·m)
  
  Notice
  
  To apply the correct torque, apply the torque wrench along the axis through the bolts of the No.1 idler pulley and exhaust camshaft timing pulley.
9. Using a feeler gauge, check the specified clearance between the tensioner body and No.1 idler pulley stopper.
  
  Clearance: 1.80 – 2.20 mm (0.071 – 0.087 in.)
Check valve timing.
1. Slowly turn the crankshaft pulley two revolutions from TDC to TDC.
  
  Notice
  
  Always turn the crankshaft clockwise.
2. Check that each pulley aligns with the timing marks as shown in the figure.
  
  If the marks do not align, remove the timing belt and reinstall it.
Install No.2 timing belt cover.
1. Install the gasket to the timing belt cover.
2. Install the belt cover with the five bolts.
Install spark plugs. (See On-vehicle inspection (3S-GTE) › Inspection of spark plugs)

Torque: 180 kg-cm (13 ft-lb, 18 N·m)
Install hose clamp and VTV clamp of air by-pass valve. (See Turbocharger › Installation of turbocharger, steps 13, 14)
Install cylinder head cover. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 7)
Install throttle body. (See steps 2, 3 and 5 to 8 on pages FI-138 and 139)
Install EGR vacuum modulator and VSV. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 20)
Install RH engine mounting bracket.

Install the mounting bracket with the three bolts.

Torque: 530 kg-cm (38 ft-lb, 52 N·m)
Install RH engine mounting insulator.

Install the mounting insulator with the through bolt and two nuts.

Torque:
- Nut – 530 kg-cm (38 ft-lb, 52 N·m)
- Through bolt – 800 kg-cm (58 ft-lb, 78 N·m)
Hint

Lower the jack and perform the operation with the engine fully up.
Install RH engine mounting stay.

Install the mounting stay with the two bolts and nut.

Torque: 740 kg-cm (54 ft-lb, 73 N·m)
Install alternator drive belt.

Install the drive belt with the adjusting bolt, lock bolt and pivot bolt.
Install RH front wheel.
Install intercooler. (See Intercooler › Installation of intercooler, steps 2–8, 10, 11)
Install cruise control actuator (w/ cruise control system) and accelerator linkage. (See step 36 Cylinder block (3S-GTE) › Installation of engine)
Install suspension upper brace. (See step 41 Cylinder block (3S-GTE) › Installation of engine)
Install RH engine hood side panel.
Install engine under covers.
Connect cable to negative terminal of battery.
Check and adjust drive belts.
1. Adjust the alternator drive belt. (See On-vehicle inspection)
  
  Drive belt tension:
  - New belt – 120 ± 20 lb
  - Used belt – 104 ± 20 lb
2. Adjust the A/C drive belt.
  
  Drive belt tension:
  - New belt – 160 ± 20 lb
  - Used belt – 100 ± 20 lb

Adjustment of valve timing¶

Remove No.2 timing belt cover. (See Timing belt (3S-GTE), steps 1–6, 9–12)
Remove spark plugs. (See On-vehicle inspection (3S-GTE) › Inspection of spark plugs)
Check camshaft timing pulley marks.
1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
  
  Notice
  
  Always turn the crankshaft clockwise.
2. Check that the timing marks of the camshaft timing pulleys are aligned with the timing mark of the No.3 timing belt cover.
  - If there is more than one timing pulley tooth between the timing marks, realign the timing marks in accordance with step 8.
  - If the timing marks are aligned or the difference is less than one timing pulley tooth, proceed to step 9.
Remove EGR vacuum modulator and VSV. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 22)
Remove throttle body. (See steps 5 to 8 and 9 to 11 on pages FI-135 and 136)
Remove hose clamp and VTV clamp of air by-pass valve. (See Turbocharger › Removal of turbocharger, steps 15, 16)
Remove cylinder head cover. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 35)
Adjust camshaft timing pulley timing marks.
1. Remove the two bolts and timing belt tensioner.
2. Remove the timing belt from the camshaft timing pulleys.
3. Rotate the camshaft with a wrench and align the alignment marks of the camshaft timing pulley and No.3 timing belt cover.
4. Reinstall the timing belt, insure that there is tension between the crankshaft timing pulley and intake camshaft timing pulley.
  
  Notice
  
  Install the timing belt when the engine is cold.
5. Install the timing belt tensioner with the two bolts. (See Installation of timing belt, steps 12, 13)
  
  Torque: 210 kg-cm (15 ft-lb, 21 N·m)
6. Turn the crankshaft pulley two revolutions from TDC to TDC.
  
  Notice
  
  Always turn the crankshaft clockwise.
7. Check that each pulley aligns with the timing marks as shown in the figure.
Check valve timing.
1. Using a wrench, turn and align the groove of the camshaft with the drilled mark of the No.1 camshaft bearing cap.
  
  Notice
  
  Always turn the crankshaft clockwise.
2. Next make a note of the crankshaft pulley angle on the No.1 timing belt cover.
  
  Hint
  
  Perform this check separately for the intake and exhaust sides.
  
  If the crankshaft pulley movement is within ± 2.4 mm (0.094 in.) of TDC, it is correct.
  
  If it is greater than 2.4 mm (0.094 in.), go back to step 8.
Adjust valve timing.
1. Hold the hexagonal wrench head portion of the camshaft with a wrench, and remove the two camshaft timing pulley bolts.
  
  Hint (intake camshaft timing pulley)
  
  Use SST.
  
  SST 09249-63010
  
  Notice
  
  Do not make use of the timing belt tension when loosening the pulley bolts.
2. Check that the camshaft grooves are aligned with the drilled mark of the No.1 camshaft bearing cap.
3. Using a magnetic finger, remove the knock pin from the pin hole of the camshaft timing pulley.
4. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
  
  Notice
  
  Always turn the crankshaft clockwise.
5. Select one overlapped hole of the camshaft and timing pulley, and insert the match pin into it.
  Hint
  - If there is no overlapped hole, rotate the crankshaft a little and insert the pin into the nearly overlapped hole.
  - By changing the pin hole to the next one, the crankshaft pulley angle can be adjusted by approx. 2°.
  - By changing the pin hole to the next two, the crankshaft pulley angle can be adjusted by approx. 5°.
6. Hold the hexagonal wrench head portion of the camshaft with a wrench, and install the pulley bolt.
  
  Torque:
  - 600 kg-cm (43 ft-lb, 59 N·m)
  - 420 kg-cm (30 ft-lb, 41 N·m) for SST
  Hint (intake camshaft timing pulley)
  - Use SST.
    
    SST 09249-63010
  - Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).
  Notice
  
  Do not make use of the timing belt tension when tightening the bolt.
7. Turn the crankshaft clockwise two revolutions from TDC to TDC.
8. Recheck the valve timing. (See Adjustment of valve timing, step 9)
Reinstall cylinder head cover. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 7)
Reinstall hose clamp and VTV clamp of air by-pass valve. (See Turbocharger › Installation of turbocharger, steps 13, 14)
Reinstall throttle body. (See steps 2, 3 and 5 to 8 on pages FI-138 and 139)
Reinstall EGR vacuum modulator and VSV. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 20)
Reinstall spark plugs. (See On-vehicle inspection (3S-GTE) › Inspection of spark plugs)

Torque: 180 kg-cm (13 ft-lb, 18 N·m)
Reinstall No.2 timing belt cover. (See steps 15, 21 to 23 and 26 to 30 Installation of timing belt)