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TIMING BELT REMOVAL

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CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed or replaced during the timing belt removal/installation are shown below.

Table 1. Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of timing belt Mode reset operation
  • Does not illuminate when replacement is necessary

  • Illuminates when replacement is not necessary

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CAUTION:
B0024U6

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

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PROCEDURE


  1. Click here

    REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  2. Click here

    REMOVE COMPRESSOR ASSEMBLY WITH MAGNET CLUTCH

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  3. Click here

    DRAIN ENGINE COOLANT

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  4. Click here

    REMOVE VANE PUMP V BELT

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  5. Click here

    REMOVE COOLER COMPRESSOR V BELT

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  6. Click here

    REMOVE FAN AND GENERATOR V BELT

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  7. Click here

    REMOVE NO. 1 RADIATOR HOSE

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  8. Click here

    DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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  9. Click here

    REMOVE OIL RESERVOIR BRACKET

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  10. Click here

    REMOVE RADIATOR RESERVOIR

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  11. Click here

    REMOVE FAN SHROUD

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  12. Click here

    REMOVE VANE PUMP DRIVE PULLEY


    1. B0025Q6

      Remove the 4 bolts, vane pump drive pulley and cooler compressor drive pulley.

  13. Click here

    REMOVE CRANKSHAFT PULLEY


    1. B0026IJC02
      *a Hold
      B0068HS Turn

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt.

      09213-54015 91651-60855
      09330-00021
      Tip:

      Make sure to leave the pulley bolt screwed into the crankshaft by 2 or 3 threads.

    2. B0028DCC02
      *a Hold
      B0068HS Turn

      Using SST, remove the crankshaft pulley.

      09950-50013 09951-05010 09952-05010 09953-05020 09954-05021
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    REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B0028J1

      Remove the bolt and disconnect the generator with vacuum pump assembly.

    2. B0026K3

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  15. Click here

    REMOVE TIMING BELT COVER


    1. B0025WR

      Remove the 11 bolts, washers, timing belt cover, and 2 timing belt cover gaskets.

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    REMOVE TIMING BELT GUIDE


    1. B00276N

      Remove the timing belt guide.

  17. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B0026GHC01
      *a Timing Mark
      B0068HS Turn

      Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.

    2. B0027UQC01
      *a Timing Mark

      Check that the timing marks of the camshaft timing pulley and No. 2 timing belt cover are aligned.

      If not, turn the crankshaft 1 revolution (360°).

  18. Click here

    REMOVE TIMING BELT

    Tip:

    If reusing the timing belt, draw a direction arrow on the timing belt (in the direction the belt moves when the engine is running), and place matchmarks on the pulleys and timing belt.


    1. B0024YKC01
      *a Timing Mark
      B0068HS Turn

      Turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case sub-assembly.

      Note:

      If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley, causing damage. Therefore, always set the crankshaft pulley at the correct angle.

    2. B00282DC01
      B006964 Pry

      Loosen the bolt, and shift the No. 1 timing belt idler sub-assembly to the left as far as possible.

    3. Tighten the bolt, and then relieve the timing belt tension.

    4. Remove the timing belt.

  19. Click here

    REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. B0028KPC01
      *1 Idler Tension Spring

      Remove the 2 bolts A and B.

    2. Loosen bolt C, and remove the No. 1 timing belt idler sub-assembly and idler tension spring.

      Tip:

      Bolt C is combined with the No. 1 timing belt idler sub-assembly.