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ENGINE MECHANISM (G15) 6A-17

Timing Belt and Tensioner Components

1. Timing belt 7. Build pulley camshaft 13. Tensioner stud bolt

2. Tensioner 8. Seal 14. Baut cover timing belt
3. Tensioner plate 9. Inside cover seal 15. Mur cover timing belt
4. Tensioner spring 10. Inside cover 25 N·m (2.5 kg-m, 18.0 lb-ft)

5. Pulley camshaft 11. Outside cover seal 11 N·m (1.1 kg-m, 8.0 lb-ft)

6. Build tensioner 12. Outside cover 60 N·m (6.0 kg-m, 43.5 lb-ft)

Removing and Installing the Timing Belt and

Tensioner
ATTENTION:
• After removing the timing belt, do not rotate the camshaft
and crankshaft separately, as shown in the figure. If
rotated, there will be chaos in the working of the piston
and valve, and other components connected to the piston
and valve may be damaged. • Do not bend
the timing belt.

1. Allowable camshaft rotation - - - With timing mark, 90° from “V” mark
on the left and right head cover
2. Allowable camshaft rotation - - - With timing marks, 90° from arrows on left and right oil
pump case
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6A-18 ENGINE MECHANISM (G15)

Removing
1) Remove the battery negative cable.
2) Drain the engine coolant and remove the inlet hose from the radiator.
3) Raise the vehicle.

4) Remove the oil pan guard member (1).

5) Remove the P/S pump belt (1) according to the procedure "Removing and
Installing the P/S Pump Belt” in Chapter 3B1.
6) Remove the water pump pulley according to the "Remove and
Installing the Water Pump” in Chapter 6B.

7) Remove the crankshaft pulley by removing the 5 pulley bolts (1).

8) Lepas timing belt outside cover (1).

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ENGINE MECHANISM (G15) 6A-19

9) To install the timing belt, align the 4 timing marks as shown in the figure
by rotating the crankshaft.

1. “V” mark on the cylinder head cover

2. Timing mark with “E” on the camshaft pulley 3.
Arrow mark on the oil pump case 4.
Mark on the crankshaft timing belt pulley

10) Lepas tensioner (6), tensioner plate (2), tensioner spring (5)
and timing belt (1).

3. Build tensioner
4. Stud bolt tensioner

Installing

1) Attach tensioner plate (3) to tensioner (4).

Attach the lug (1) of the tensioner plate to the hole (2) on the tensioner.

2) Install the tensioner (2) and tensioner plate (3):

Temporarily tighten the tensioner bolt (1) by hand.
Check the plate movement in the direction of the arrow as shown in the
picture, make sure the tensioner moves in the same direction.
If the movement between the plate and tensioner is not related, remove
the tensioner and plate again and reattach the plate lug to the tensioner
hole.

3) Check that the timing mark “E” (2) on the camshaft pulley (3) is aligned
with the “V” mark (1) on the cylinder head cover as shown in the figure.
If not, align the two marks by rotating the camshaft, being careful not to
exceed the allowable speed limit as described in "Warning" and
"Removing and Attaching the Timing Belt and Tensioner".
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6A-20 ENGINE MECHANISM (G15)

4) Check that the mark (2) on the crankshaft timing belt pulley (3) is
aligned with the arrow (1) on the oil pump case as shown in the
figure. If not, align the two marks with crankshaft rotation being
careful not to exceed the allowable speed limit as described in
“Caution” and “Removing and Installing Timing Belt and Tensioner”.

5) Install timing belt (1) and spring tensioner (2).

While observing the alignment of the two marks, press the tensioner
plate up and install the timing belt on both pulleys until the drive side
belt (1) can move freely.
Then install the tensioner spring as shown in the illustration, and
tighten the tensioner stud bolt (3) by hand.

NOTES:

• When installing the timing belt, align the arrows (ÿ) on the timing
belt with the direction of rotation of the crankshaft. • In this
condition, the No.4 piston is in the top dead center position of
the compression stroke.

4. Damper

6) To retract a loose portion of the timing belt (1), rotate the crankshaft
two revolutions clockwise after the timing belt is engaged. After
making sure the timing belt is not loose, tighten the tensioner stud
bolt (2) first and then the tensioner bolt (3) to the specified torque.

Make sure both pairs of marks are straight.

Tensioner stud bolt

tightening moment (a): 11 N m (1.1 kg-m, 8.0 lb-ft)
Tensioner bolt (b): 25 N·m (2.5 kg-m, 18.0 lb-ft)

7) Install the timing belt cover (1).

Before installing, make sure there is a seal between the water pump
and the oil pump case.

Timing belt cover bolt

tightening moment (a): 11 N m (1.1 kg-m, 8.0 lb-ft)
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ENGINE MECHANISM (G15) 6A-21

8) Install the crankshaft pulley (2).

Align the pulley hole to the pin (1) on the crankshaft pulley, and tighten
the pulley bolt (3) to the specified torque.

Crankshaft pulley bolt

tightening moment (a): 16 N m (1.6 kg-m, 11.5 lb-ft)

9) Install the water pump pulley according to the procedure “Removing and
Installing the Water Pump” in Chapter 6B.
10) Install the water pump belt according to the "Removing and Installing
the Water Pump/Generator Belt" procedure in Chapter 6B.
11) Install the P/S pump belt according to the procedure “Removing and
Installing the P/S Pump Belt” in Chapter 3B1.

12) Attach the oil pan guard member (1) to the body.
13) Attach the radiator inlet hose to the radiator.
14) Refill the cooling system according to the procedure “Draining and
Recharging Cooling System” in Chapter 6B.
15) Connect the negative battery cable.
16) Make sure there are no coolant leaks at the hose connections.

Check Timing Belt and Tensioner

• Check the timing belt for wear or cracks.
Replace if necessary.

• Check tensioner rotation.

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ENGINE COOLING 6B-15

Removing and Installing Belt Water Pump/

Generator
Let go

1) Remove the battery negative cable.

2) If the vehicle is equipped with A/C, remove the A/C compressor belt (4)
“

before removing the water pump belt (1). See Removing and Installing the
Compressor Assy.” in Chapter 1B.
3) Loosen generator adjusting bolt (2) and part bolt
under the generator (5).
4) Loosen the generator adjuster bolt (3) to shift the generator adjuster and
then remove the water pump belt.

Installing

1) Attach belt (1) to water pump pulley (2), crankshaft pulley (3) and generator
pulley (4).
2) Adjust the belt tension according to the procedure “Checking and Adjusting
the Water Pump/Generator Belt”.
3) If the vehicle is equipped with an A/C, install the A/C compressor belt (5)
according to the procedure “Removing and Attaching the Compressor
Assy.” in Chapter 1B.
4) Connect the negative battery cable.

Removing and Installing the Water Pump

Let go

1) Remove the battery negative cable.

2) Drain the coolant according to the procedure “Draining the Coolant System
gin”.
3) Remove the center member of the engine room with the gear shift control
lever and parking brake lever.
4) Remove the water pump/generator belt according to the "Removing and
Installing the Water Pump/generator Belt" procedure.
5) Remove the timing belt according to the procedure "Removing & Installing
Timing Belt and Tensioner" in Chapter 6A.
6) Lepas water pump assembly (1).
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6B-16 ENGINE COOLING

Installing

Reverse the removal to install procedure by paying attention to the following

points.
1) Install a new water pump gasket on the cylinder block.
2) Install the water pump assembly (2) onto the cylinder block and tight
tighten bolts and nuts to specification.

Water pump nut and bolt

tightening moment (a) : 11 N m (1.1 kg-m, 8.0 lb-ft)

3) Install the rubber seal (1) between the water pump and the oil pump, and
the other between the water pump and the cylinder head.
4) Install the timing belt according to the “Removing & Attaching the Timing
Belt and Tensioner” procedure in Chapter 6A.
5) Install the water pump/generator belt according to the procedure
“Removing and Installing the Water Pump/Generator Belt”.
6) Install the A/C compressor belt (if equipped) according to the “Removing
and Attaching Compressor Assy” procedure in Chapter 1B.
7) Refill the cooling system according to steps 7) to 20) in “Draining and
Recharging the Cooling System”.
8) Connect the negative battery cable.
9) Check all components for leaks.

Checking the Water Pump

NOTES:

Do not disassemble the water pump.

If the water pump needs repair, replace it assy.

1) Turn the water pump by hand to check its rotation. If the pump does not
turn easily or a rumble occurs, replace it.

2) Check the water pump impeller for damage.

Replace if necessary.

Removing and Installing Engine Coolant

Temperature (ECT) Sensor
See “Removing and Installing the Engine Coolant Temperature (ECT) Sensor”
in Chapter 6E.

Checking the Engine Coolant Temperature (ECT) Sensor See

“Checking the Engine

Coolant Temperature (ECT) Sensor” in Chapter 6E.