Hello,
check the steps and the diagrams below how to remove and reinstall valve timing belt.
Removal:
1. Remove front wheel RH
2. Remove front wiper arm head cap.
3. Remove front wiper arms RH and LH. (Check below fig 1, 2, 3)
4. Remove cowl top ventilator louver sub-assembly.
5. Remove wiper link assembly.
6. Remove No 1 cowl top to cowl brace inner.
7. Remove cowl top panel sub-assembly outer front.
8. Remove front fender apron seal RH.
9. Remove No1 V belt.
10. Remove vane pump V belt.
11. Remove engine moving control rod.
A. Remove the 5 bolt, the engine moving control rod and the engine mounting stay.(Fig4)
12. Remove engine mounting stay No2 RH(fig5)
a. Remove the bolt and the wire harness bracket.
B. Remove the bolt. The No2 engine mounting stay and the No2 engine mounting bracket.
13. Remove No 2 generator bracket.(Fig6)
a. Remove the nut and the generator bracket.
14. Remove crankshaft pully.
A. Using SST loosen the pully bolt.
SST 09213-54015(91651-60855)09330-00021(fig7)
b. Using SST and the pully bolt remove the pulley
SST 09950-50013(fig8)
NOTICE before using SST apply lubricating oil on the thread and the tip of the center bolt 150.
15. Remove timing belt No1 cover.
16. Remove timing belt No2 cover
a, disconnect the engine wire protector clamps from the timing belt No3 cover.(Fig9)
b. Remove the 5 bolts and the timing belt cover.
17. Remove engine mounting bracket RH.
A. Remove the 2bolts the nut and the engine mounting bracket RH.(Fig10)
18. Remove No 2 timing belt guide.
19. Remove timing belt.
A. Set No1 cylinder to TDC compression.(Fig11)
20. Temporarily install the crankshaft pulley bolt and the washer to the crankshaft.
21. Turn the crankshaft clockwise and align the timing marks of the crankshaft timing pulley and the oil pump body.
22. Check that timing marks of the camshaft timing pulleys and the No3 timing belt cover are aligned if not turn the crankshaft 1 revolution 360 degree.(Fig12)
23. Remove the crankshaft pulley bolt.
A. If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the picture.(Fig13)
24. If the installation marks have disappeared put new installation marks on the timing belt before removing.
A. Set No1 cylinder to 60 degree BTDC compression.
25. Turn the crankshaft counterclockwise by approximately 60 degree.(Fig 14)
NOTICE if the timing belt is disengaged having the crankshaft pulley at the wrong angle can cause the piston head and the valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft causing damage. So always set the crankshaft pulley at the correct angle.
26. Remove the timing belt tensioner.
NOTICE do not install the tensioner as it removed.
27. Remove the timing belt in this order.(Fig15, 16)
installation.
1. Remove any oil or water in the pulleys and keep them clean.
2inspect idler pulleys must turn smoothly
3. Inspect water pump
4. Temporarily install the crankshaft pulley bolt and the washer to the crankshaft.
5. Turn the crankshaft counterclockwise by 60degree BTC(fig 17)
6, using SST turn the camshaft pulley and align the timing marks of the timing pulley and the No 3 timing belt cover(fig 18)
SST09960-10010
7. Turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body.(Fig 19)
8. Face the front mark on the timing belt forward, align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley, align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.(Fig20)
9. Install the timing belt in this order(fig21, 22)
10. Install No1 chain tensioner assembly,
11. Set the timing belt tensioner upright on the press(fig 23), slowly press in the push rod, do not apply pressure more than 9.8KN.
Align the holes of the push rod and housing pass 1.5mm hexagon wrench through the holes to keep the setting position of the push rod.
Release the press. Temporarily install the tensioner with the 2 bolts, tighten the 2 bolts 27NM
remove the 1.5mm hexagon wrench from the tensioner.
12. Turn the crankshaft 2 revolution and align the timing marks of the crankshaft timing pulley and the oil pump body. Always turn the crankshaft clockwise(fig24)
13. Check the timing marks of the RH and LH timing pulleys are aligned with the marks of 3 timing belt covers shown in the picture, if the marks do not align remove the timing belt and reinstall it(fig25)
14, install the No 2 timing belt guide, install the guide facing the cup side toward the engine front.(Fig26)
15, install all the removed parts in reverse order of the removal.(Fig 27, 28)
hope these helps, let us know if you need more help.
Thank you.
.
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Friday, January 29th, 2021 AT 3:07 PM