ENGINE MECHANICAL 11A-43

TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1112004302889

Pre-removal and Post-installation Operation

x Water Pump Pulley Removal and Installation (Refer to
GROUP 14  Radiator Fan P.14-6).
x Crankshaft Pulley Removal and Installation (Refer to
P.11A-17).

<Except Euro5>

3.0 ± 0.5 N·m

10
3
4 10 ± 2 N·m
48 ± 6 N·m

9
7
42 ± 8 N·m 44 ± 10 N·m

2 10
44 ± 10 N·m
23 ± 3 N·m

6
10 ± 2 N·m
5 AC805880 AB

Removal steps Removal steps (Continued)

1. Engine cover 6. Timing belt lower cover
2. Harness bracket >>D<< 7. Auto tensioner
3. Timing belt upper cover <<A>> >>D<< 8. Timing belt
4. Auto tensioner >>D<< 9. Tensioner arm assembly
5. Harness bracket 10. Idler pulley
11A-44 ENGINE MECHANICAL
TIMING BELT

23 ± 3 N·m
16

15
14
20 ± 4 N·m

13

11 12
AC502913 AE

Removal steps Removal steps (Continued)

>>C<< 11. Crankshaft sprocket >>A<< 15. Tensioner B spring
>>C<< 12. Flange >>A<< 16. Timing belt B tensioner assembly
<<B>> >>B<< 13. Timing belt B
>>A<< 14. Tensioner B spacer
 ENGINE MECHANICAL 11A-45
TIMING BELT

<Euro5>

3.0 ± 0.5 N·m

11

5 10 ± 2 N·m 4
48 ± 6 N·m
42 ± 8 N·m
10
8
44 ± 10 N·m
2
10 ± 2 N·m 11
44 ± 10 N·m
3 23 ± 3 N·m

7
10 ± 2 N·m
10 ± 2 N·m 6
AC805668 AB

Removal steps Removal steps (Continued)

1. Engine cover 6. Harness bracket
2. Harness bracket 7. Timing belt lower cover
3. Solenoid valve and harness bracket >>D<< 8. Auto tensioner
assembly <<A>> >>D<< 9. Timing belt
4. Timing belt upper cover >>D<< 10. Tensioner arm assembly
5. Auto tensioner 11. Idler pulley
11A-46 ENGINE MECHANICAL
TIMING BELT

23 ± 3 N·m
17

16
15
20 ± 4 N·m

14

12 13
AC502913 AF

Removal steps REMOVAL SERVICE POINTS

>>C<< 12. Crankshaft sprocket <<A>> TIMING BELT REMOVAL
>>C<< 13. Flange
<<B>> >>B<< 14. Timing belt B CAUTION
>>A<< 15. Tensioner B spacer Never turn the crankshaft anti-clockwise.
>>A<< 16. Tensioner B spring
>>A<< 17. Timing belt B tensioner assembly Timing mark
Camshaft
sprocket

Timing mark

Timing
mark Injection pump
sprocket

Crankshaft
sprocket AC502914AB

1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.
 ENGINE MECHANICAL 11A-47
TIMING BELT

CAUTION INSTALLATION SERVICE POINTS

To reuse the timing belt, draw an arrow indicating >>A<< TIMING BELT B TENSIONER ASSEMBLY/
the rotating direction (clockwise) on the back of TENSIONER B SPRING/TENSIONER B SPACER
the belt using chalk, etc. INSTALLATION
Timing belt B
Timing belt tensioner
assembly

Flange
bolt

Water
AC502915AB
pump
2. Remove the timing belt.
Hexagon
socket
<<B>> TIMING BELT B REMOVAL head bolt
CAUTION Tensioner B
To reuse the timing belt B, draw an arrow indicat- spacer
Front lower case
ing the rotating direction on the back of the belt
using chalk, etc.

Washer
Tensioner B spring AC502918AB

1. Install the timing belt B tensioner assembly,

tensioner B spring and tensioner B spacer.
Timing NOTE: Be sure to install the tensioner B spring
belt B with its shorter end toward the water pump.
2. Move timing belt B tensioner assembly toward
AC502917AB
water pump and tighten mounting bolts.

1. Loosen the timing belt B tensioner assembly >>B<< TIMING BELT B INSTALLATION
mounting bolts.
Balancer
2. Push the timing belt B tensioner assembly to Timing mark shaft
water pump side and tighten the timing belt B sprocket
Timing mark
tensioner assembly mounting bolts.
Timing mark
3. Remove the timing belt B.
Timing belt B

Crankshaft
Balancer sprocket B
shaft sprocket AC502919AB

1. Align timing marks on the crankshaft sprocket B,

and balancer shaft sprockets with their timing
marks.
2. Install balancer timing belt B onto sprockets and
ensure that its tension side is not slack.
11A-48 ENGINE MECHANICAL
TIMING BELT

Timing belt B NOTE: Also clean the degreased surfaces.

tensioner
assembly Flange Timing mark
bolt

Flange

Hexagon socket
head bolt

AC502920AB

3. Loosen timing belt B tensioner assembly
mounting flange bolt, one to two turns.
4. Tighten the timing belt B tensioner assembly
mounting hexagon socket head bolt.
5. timing belt B tensioner assembly mounting flange
bolt.
NOTE: If the bolt is tightened first, the timing belt
B tensioner assembly should be turned together,
resulting in reduced timing belt B tensioner
assembly.
Balancer shaft
sprocket
Belt
deflection
Crankshaft
sprocket B
AC502921AB
6. Ensure that the deflection is as specified when the
timing belt B is pushed by the index finger at the
position indicated by an arrow.
AC502923 AB
2. Assemble the flange by aligning the timing mark
of the front lower case and the timing mark of the
flange.
>>D<< TENSIONER ARM ASSEMBLY/TIMING
BELT/AUTO TENSIONER INSTALLATION
1. To reuse the auto tensioner, bleed the air
according to the procedure below, and then set
the rod to the auto tensioner.
CAUTION
x If a horizontal press such as a vice is used,
the air entrainment may occur. Thus, a verti-
cal press must be used.
x If the compression is too fast, the procedure
may damage the rod. Make sure to compress
slowly and thoroughly.
x To prevent a damage to the auto tensioner, do
not push down the rod exceeding the bottom
end (a position where the rod protrusion is at
0.5 mm from the auto tensioner).
Press Rod

Belt deflection: 4  5 mm

>>C<< FLANGE/CRANKSHAFT SPROCKET Auto tensioner

INSTALLATION

Crankshaft
Crankshaft sprocket B
Flange AC502924 AB
sprocket
Crankshaft
(1) Set the auto tensioner to the vertical press,
and then slowly compress the rod to the
bottom end (a position where the rod
protrusion is at 0.5 mm from the auto
tensioner). Perform this operation 2 to 3 times.
(2) With the rod protruding (a position where the
AC502922AB rod protrusion is at 5 mm from the auto
tensioner), check that there is a rigidity when
1. Clean or degrease the crankshaft, the flange and the rod is pushed with a load (100 to 200 N).
crankshaft sprocket as shown.
 ENGINE MECHANICAL 11A-49
TIMING BELT

(3) If the rod rigidity is not obtained by repeating

the operations of (1) and (2), replace the auto Camshaft Timing mark
tensioner. sprocket

B
Rod
A Timing mark

Auto tensioner

AC502924 AC

(4) Compress the rod slowly, and then align the

set hole A of the rod with the set hole B of the Timing
auto tensioner body. mark Injection pump
sprocket
Wire or pin
Crankshaft
sprocket AC502916AB

Auto tensioner
4. Align the timing mark of each sprocket.

Crankshaft Crankshaft
sprocket Slide sprocket B

Crankshaft

AC502925AB

(5) Insert a wire or pin in the aligned set hole. Key top end
NOTE: When the auto tensioner is replaced
with a new part, the auto tensioner is set with a
pin.
Notched area AC502926AB
2. Install the auto tensioner in position. Leave the
wire or pin installed until the auto tensioner is 5. In the order below, install the timing belt without
completely installed. slack.
3. Install the tensioner arm assembly. NOTE: When installing the timing belt into the
crankshaft sprocket, slide the crankshaft sprocket
to near the tip of the key, and then install the tim-
ing belt. (When installing the timing belt, be care-
ful not to damage the belt by the cut-out of
crankshaft sprocket.) After that, install the crank-
shaft sprocket to the correct position.
(1) Crankshaft sprocket
(2) Idler pulley
(3) Injection pump sprocket
(4) Idler pulley
(5) Camshaft sprocket
(6) Tensioner pulley
6. Check that the timing marks on sprockets are at
the correct positions.
7. Remove the wire or pin of the auto tensioner.