EM–30 ENGINE MECHANICAL
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Timing Belt (4A–FE)
TIMING BELT (4A–FE) COMPONENTS
REMOVAL OF TIMING BELT 1. REMOVE RH FRONT WHEEL 2. REMOVE RH ENGINE UNDER COVER 3. REMOVE WASHER TANK 4. LOOSEN WATER PUMP PULLEY BOLTS AND REMOVE ALTERNATOR DRIVE BELT (a) Stretch the belt tight and loosen the water pump pulley bolts. (b) Loosen the pivot nut and adjusting bolt, and remove drive belt.
EM–31 ENGINE MECHANICAL
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Timing Belt (4A–FE)
5. (with A/C) REMOVE A/C COMPRESSOR DRIVE BELT (a) Loosen the idler pulley mount bolt A. (b) Loosen the adjusting bolt B and remove the drive belt.
6. (w/ PS) REMOVE PS PUMP DRIVE BELT (a) Loosen the pivot and lock bolts. (b) Swing PS pump toward the engine and remove the drive belt.
7. DISCONNECT ENGINE WIRE FROM NO.3 TIMING BELT COVER (a) Disconnect the following connectors and wire: • Alternator connector • Alternator wire • Oil pressure switch connector • (with A/C) Compressor connector (b) Remove the bolt. (c) Disconnect the wire clamp from the wire bracket, and disconnect the engine wire from the timing belt cover. 8. REMOVE SPARK PLUG (a) Disconnect the high–tension cord from spark plug. (b) Using a plug wrench (16 mm), remove the spark plugs.
9. REMOVE CYLINDER HEAD COVER (a) Disconnect the PCV hoses from the cylinder head cover. (b) Remove the three cap nuts, grommet and cylinder head cover with the gasket.
EM–32 ENGINE MECHANICAL
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Timing Belt (4A–FE)
10. SET NO.1 CYLINDER AT TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with the No.1 timing belt cover. (b) Check that the valve lifters on the No. 1 cylinder are loose. If not, turn the crankshaft pulley one complete revolution (360).
11. REMOVE RH ENGINE MOUNTING INSULATOR (a) Set the jack to the engine. HINT: Place a wooden block between the jack and engine.
(b) Remove the three bolts and mounting stay.
(c) Remove the bolt, two nuts, through bolt and RH mounting. 12. REMOVE WATER PUMP PULLEY
13. REMOVE CRANKSHAFT PULLEY (a) Using SST to hold the crankshaft pulley, remove the pulley bolt. SST 09213–14010 and 09330–00021
EM–33 ENGINE MECHANICAL
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Timing Belt (4A–FE)
(b) Using SST, remove the pulley. SST 09213–31021
14. REMOVE TIMING BELT COVERS Remove the nine bolts, engine wire bracket and timing belt covers. 15. REMOVE TIMING BELT GUIDE
16. REMOVE TIMING BELT AND IDLER PULLEY HINT: If reusing the timing belt, draw a direction arrow on the belt (in direction of engine revolution), and place matchmarks on the pulleys and belt as shown in the illustration.
(a) Remove the bolt, idler pulley and tension spring. (b) Remove the timing belt. 17. REMOVE CRANKSHAFT TIMING PULLEY
18. REMOVE CAMSHAFT TIMING PULLEY Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt and timing pulley. NOTICE: Be careful not to damage the cylinder head with the wrench.
EM–34 ENGINE MECHANICAL
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Timing Belt (4A–FE)
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: (a) Premature splitting • Check for proper installation. • Check the timing cover gasket for damage and proper installation.
(b) If the belt teeth are cracked or damaged, check to see if either camshaft, water pump is locked.
(c) 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.
(d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
EM–35 ENGINE MECHANICAL
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Timing Belt (4A–FE)
(e) If there is noticeable wear on the belt teeth, check the timing cover for damage and check for correct gasket installation and for foreign material on the pulley teeth. If necessary, replace the timing belt.
2. INSPECT IDLER PULLEY Check the turning smoothness of the idler pulley. If necessary, replace the idler pulley.
3. INSPECT TENSION SPRING (a) Measure the free length of the tension spring. Free length: 38.4 mm (1.512 in.) If the free length is not as specified, replace the tension spring. (b) Measure the tension of the tension spring at the specified installed length. Installed tension: 3.6–4.0 kg (7.9–8.81b,35–39N–m) at 50.2 mm (1.976 in.) If the tension is not as specified, replace the tension spring.
EM–36 ENGINE MECHANICAL
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Timing Belt (4A–FE)
INSTALLATION OF TIMING BELT
(See page EM–30) 1. INSTALL CAMSHAFT TIMING PULLEY (a) Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the pulley. (b) Temporarily install the timing pulley bolt. (c) Hold the hexagonal wrench head portion of the camshaft with a wrench, and tighten the timing pulley bolt. Torque: 600 kg–cm (43 ft–Ib, 59 N–m)
(d) Turn the hexagonal wrench head portion of the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap.
2. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the pulley. (b) Slide on the timing pulley, facing the flange side inward. (c) Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body.
3. TEMPORARILY INSTALL IDLER PULLEY AND TENSION SPRING (a) Install the idler pulley with the bolt. Do not tighten the bolt yet. (b) Install the tension spring. (c) Push the pulley toward the left as far as it will go and tighten the bolt.
4. INSTALL TIMING BELT NOTICE: The engine should be cold.
HINT: If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.
EM–37 ENGINE MECHANICAL
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Timing Belt (4A–FE)
5. CHECK VALVE TIMING AND TIMING BELT TENSION (a) Loosen the timing belt idler pulley mount bolt.
(b) Temporarily install the crank pulley bolt and turn the crankshaft two revolutions from TDC to TDC. HINT: Always turn the crankshaft clockwise.
(c) Check the valve timing. Ensure that each pulley aligns with the marks as shown in the illustration.
(d) Tighten the timing belt idler pulley mount bolt. Torque: 375 kg–cm (27 ft–Ib, 37 N–m)
(e) Remove the temporarily installed crank pulley bolt.
(Reference) (a) Measure the timing belt deflection as shown in the illustration. Timing belt deflection: 5 – 6 mm (0.20 – 0.24 in.) at 2 kg (4.4 Ib, 20 N )
EM–38 ENGINE MECHANICAL
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Timing Belt (4A–FE)
(b) If the measured value is not within standard, readjust with the idler pulley.
6. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward.
7. INSTALL TIMING BELT COVERS (a) Install the timing belt cover with the three bolts. (b) Install the No.2, No.3 timing belt covers and engine wire bracket with the six bolts. Torque: 75 kg–cm (^5 in–Ib, 7.4 N–m)
8. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, slide on the pulley. (b) Temporarily install the pulley bolt. (c) Using SST, install the pulley bolt. SST 09213–14010 and 09330–00021 Torque: 1,200 kg–cm (87 ft–Ib, 118 N–m)
9. TEMPORARILY INSTALL WATER PUMP PULLEY 10. INSTALL RH ENGINE MOUNTING INSULATOR (a) Install the RH mounting insulator to the engine mounting bracket with the two nuts and bolt. Align the RH mounting insulator with the body bracket and install the mounting through bolt and nut. Torque: Bolt 650 kg–cm (47 ft–Ib, 64 N–m) Nut 530 kg–cm (38 ft–Ib, 52 N–m) Through bolt 890 kg–cm (64 ft–Ib, 87 N–m)
EM–39 ENGINE MECHANICAL
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Timing Belt (4A–FE)
(b) Install the RH mounting stay with the three bolts. Torque: 430 kg–cm (31 ft–Ib, 42 N–m)
(c) Remove the jack.
11. INSTALL CYLINDER HEAD COVER (a) Apply seal packing as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent HINT: Clean the indicated portions by removing the original sealant before recoating.
(b) Install the cylinder head cover with the three grommet and bolts. (c) Install the PCV hoses.
12. INSTALL SPARK PLUG (a) Using a plug wrench (16 mm), install the spark plugs. Torque: 180 kg–cm (13 ft–Ib, 18 N–m)
(b) Connect the high–tension cords to spark plugs.
13. CONNECT ENGINE WIRE TO NO.3 TIMING BELT COVER (a) Connect the engine wire to the timing belt cover, and connect the wire clamp to the wire bracket. (b) Install the bolt. (c) Connect the following connectors and wire: • Alternator connector • Alternator wire • Oil pressure switch connector • (with A/C) Compressor connector
EM–40 ENGINE MECHANICAL
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Timing Belt (4A–FE)
14. TEMPORARILY INSTALL WATER PUMP PULLEY Install the water pump pulley and partially tighten the four bolts. 15. (wI PS) INSTALL PS PUMP DRIVE BELT 16. (with A/C) INSTALL A/C COMPRESSOR DRIVE BELT 17. INSTALL ALTERNATOR DRIVE BELT 18. ADJUST DRIVE BELTS Using a belt tension gauge, check the drive belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) or Borroughs No. BT–33–73F Drive belt tension: Alternator New belt 160 ± 20 Ib Used belt 130 ± 20 Ib PS New belt 125 ± 25 Ib Used belt 80 ± 20 Ib A/C New belt 160 ± 20 Ib Used belt 100 ± 20 Ib If necessary, adjust the drive belt tension. HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove at the bottom of the crank pulley. • After installing a new belt, run the engine for about 5 minutes and then recheck the tension. 19. TIGHTEN WATER PUMP PULLEY BOLTS 20. INSTALL WASHER TANK 21. INSTALL RH ENGINE UNDER COVER 22. INSTALL RH FRONT WHEEL
