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Timing belt (5S-FE)

Components

Removal of timing belt

  1. 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.

  2. Remove engine under covers.

  3. Remove RH engine hood side panel.
  4. Remove suspension upper brace. (See Cylinder block (5S-FE) › Removal of engine, step 8)
  5. Remove cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (5S-FE) › Removal of engine, step 11)
  6. Remove RH front wheel.

  7. Remove A/C drive belt.

    Loosen the idler pulley bolt and adjusting bolt, and remove the drive belt.

  8. Remove alternator drive belt.

    Loosen the pivot bolt, adjusting lock bolt and adjusting bolt, and remove the drive belt.

  9. Slightly jack up engine.

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

  10. Remove RH engine mounting stay.

    Remove the bolt, nut and mounting stay.

  11. Remove RH engine mounting insulator.

    Remove the through bolt, two nuts and mounting insulator.

  12. 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.

  13. Remove No.2 timing belt cover.

    Remove the five bolts, timing belt cover and two gaskets.

  14. Remove spark plugs. (See On-vehicle inspection (5S-FE) › Inspection of high-tension cords)

  15. 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. Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap.

      If not, turn the crankshaft one revolution (360°).

  16. Remove timing belt from camshaft timing pulley.

    Hint (when re-using timing belt)

    Place the matchmarks on the timing belt and camshaft timing pulley, and place matchmark on the timing belt to match the end of the No.1 timing belt cover.

    1. Loosen the mount bolt of the No.1 idler pulley and shift the pulley toward the left as far as it will go, temporarily tighten it.

    2. Remove the timing belt from the camshaft timing pulley.

  17. Remove camshaft timing pulley.

    Using SST, remove the bolt, plate washer and timing pulley.

    SST 09249-63010 and 09278-54012

  18. Remove crankshaft pulley.

    1. Using SST, remove the pulley bolt.

      SST 09213-54015 (09214-00030) 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 "0" 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 09213-60017 (09213-00020, 09213-00030, 09213-00050)

      Hint (when re-using timing belt)

      Remove the pulley without turning it.

  19. Remove No.1 timing belt cover.

    Remove the four bolts, timing belt cover and gasket.

  20. Remove timing belt guide.

  21. Remove timing belt.

    Hint (when re-using timing belt)

    Draw a direction arrow on the timing belt (in direction of engine revolution), and place the matchmarks on the timing belt and crankshaft timing pulley.

  22. Remove No.1 idler pulley and tension spring.

    Remove the bolt, pulley and tension spring.

  23. Remove No.2 idler pulley.

    Remove the bolt and pulley.

  24. Remove crankshaft timing pulley.

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

    Hint

    Position shop rags as shown to prevent damage.

  25. Remove oil pump pulley.

    Using SST, remove the nut and pulley.

    SST 09616-30011

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:

    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 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, and correct gasket installation and the foreign material on the pulley teeth.

      If necessary, replace the timing belt.

  2. Inspect idler pulleys.

    Check the turning smoothness of the idler pulley.

    If necessary, replace the idler pulley.

  3. Inspect tension spring.

    1. Measure the free length of the tension spring.

      Free length: 46.0 mm (1.811 in.)

      If the free length is not as specified, replace the tension spring.

    2. Measure the tension of the tension spring at the specified installed length.

      Installed tension: 4.75 – 5.25 kg (10.5 – 11.6 lb, 47 – 52 N·m) at 50.5 mm (1.988 in.)

      If the installed tension is not as specified, replace the tension spring.

Installation of timing belt

(See Components)

  1. Install oil pump pulley.

    1. Align the cutouts of the pulley and shaft, and slide on the pulley.
    2. Using SST, install the nut.

    SST 09616-30011

    Torque: 290 kg-cm (21 ft-lb, 28 N·m)

  2. Install crankshaft timing pulley.

    1. Align the timing pulley set key with the key groove of the pulley.
    2. Slide on the timing pulley, facing the flange side inward.

  3. Install No.2 idler pulley.

    1. Install the pulley with the bolt.

      Torque: 425 kg-cm (31 ft-lb, 42 N·m)

      Hint

      Use bolt 35 mm (1.38 in.) in length.

    2. Check that the idler pulley moves smoothly.

  4. Temporarily install No.1 idler pulley and tension spring.

    1. Install the pulley with the bolt. Do not tighten the bolt yet.

      Hint

      Use bolt 42 mm (1.65 in.) in length.

    2. Install the tension spring.

    3. Pry the pulley toward the left as far as it will go and tighten the bolt.
    4. Check that the idler pulley moves smoothly.

  5. 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.

  6. Install timing belt guide.

    Install the guide, facing the cup side outward.

  7. Install No.1 timing belt cover.

    1. Install the gasket to the timing belt cover.
    2. Install the timing belt cover with the four bolts.

  8. Install crankshaft pulley.

    1. Align the pulley set key with the key groove of the pulley, slide on the pulley.

    2. Using SST, install the pulley bolt.

      SST 09213-54015 (09214-00030) and 09330-00021

      Torque: 1,100 kg-cm (80 ft-lb, 108 N·m)

  9. Install camshaft timing pulley.

    1. Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the timing pulley.

    2. Using SST, install the plate washer and bolt.

      SST 09249-63010 and 09278-54012

      Torque: 380 kg-cm (27 ft-lb, 37 N·m)

      Hint

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

  10. 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. Using SST, turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap.

      SST 09278-54012

  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 Removal of timing belt)

    • Align the matchmarks of the timing belt and camshaft timing pulley.

    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 camshaft timing pulley.

  12. Check valve timing.

    1. Loosen the No.1 idler pulley bolt ½ turn.

    2. Turn the crankshaft pulley two revolutions from TDC to TDC.

      Notice

      Always turn the crankshaft clockwise.

    3. Check that each pulley aligns with the timing marks as shown in the figure.

      If the timing marks do not align, remove the timing belt and reinstall it.

    4. Torque the mount bolt of the No.1 idler pulley.

      Torque: 425 kg-cm (31 ft-lb, 42 N·m)

  13. Install spark plugs. (See On-vehicle inspection (5S-FE) › Inspection of spark plugs)

    Torque: 180 kg-cm (13 ft-lb, 18 N·m)

  14. Install No.2 timing belt cover.

    1. Install the two gaskets to the No.1 and No.2 belt covers.

    2. Install the belt cover with the five bolts.

    3. Install the two clamps of the engine wire to each bolt.

  15. Install RH engine mounting bracket.

    Install the bracket with the three bolts.

    Torque: 530 kg-cm (38 ft-lb, 52 N·m)

    Hint

    Lower the jack and perform the operation with the engine fully up.

  16. 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)

  17. Install RH engine mounting stay.

    Install the mounting stay with the bolt and nut.

    Torque: 740 kg-cm (54 ft-lb, 73 N·m)

  18. Install alternator drive belt.

    Install the drive belt with the adjusting bolt, lock bolt and pivot bolt.

  19. Install A/C drive belt.

    Install the drive belt with the adjusting bolt and idler pulley bolt.

  20. Install RH front wheel.

  21. Install cruise control actuator (w/ cruise control system) and accelerator linkage. (See step 33 Cylinder block (5S-FE) › Installation of engine)
  22. Connect cable to negative terminal of battery.

  23. 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

  24. Install suspension upper brace. (See Cylinder block (5S-FE) › Installation of engine, step 36)

  25. Install RH engine hood side panel.
  26. Install engine under covers.