Removal
Warning: If your radio has an anti-theft code, make sure you have the connection codes before disconnecting the battery.
Caution! On models from 1993 onwards, the airbag system is disabled if the battery is disconnected for an extended period of time. If the airbag warning light comes on and remains on after the battery is reconnected, contact a specialist workshop to restore the system to working order.
Elements of the valve timing drive mechanism
1 – crankshaft pulley drive belt; 2 – right engine mount; 3 – Upper timing belt casing; 4 – gasket; 5 – toothed belt; 6 – Idle pulley No.2; 7 – right camshaft pulley; 8 – left camshaft pulley; 9 – crankshaft pulley; 10 – toothed belt guide; 11 – Idle pulley No.1; 12 – timing belt tensioning mechanism; 13 – dust cover; 14 – lower toothed belt casing
1. Remove the ground cable from the battery.
2. Remove the coolant from the expansion tank and the fluid from the windshield washer reservoir.
3. Remove the cruise control actuator and vacuum pump.
4. Remove the drive belts from the alternator and power steering pump.
5. Raise the front of the car and secure it on stands. Remove the right front wheel.
6. Remove the right front wheel arch protection.
7. On the 3VZ–FE engine, remove the power steering fluid reservoir without disconnecting the hoses from it and move it to the side.
8. Support the engine with a jack and remove the right powertrain mount with the bracket.
9. Remove the spark plugs.
10. Remove the upper timing belt cover together with the gasket.
11. Set the piston of the first cylinder to TDC in the compression stroke.
12. Check for timing marks on the timing belt. If the marks are worn off and the timing belt is to be reinstalled, re-mark it.
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13. Check that the timing marks on the camshaft pulleys are aligned with the pointers.
14. Remove the timing belt tensioner mechanism.
15. Reduce the tension of the timing belt between the camshaft pulleys by turning the rear pulley clockwise.
16. If the timing belt is to be reinstalled, place a mark on the outside of the timing belt level with the top edge of the lower timing belt cover.
17. Remove the timing belt from the camshaft pulleys.
18. If the camshaft pulleys are worn or damaged, replace them. To do this, remove the cylinder head cover, secure the camshaft with a wrench to prevent it from turning, and unscrew the pulley mounting bolt. Remove the pulley from the camshaft.
19. Remove the upper idler pulley.
20. Unscrew the crankshaft pulley mounting bolt, while using a screwdriver to secure the crankshaft from turning by the flywheel ring gear teeth.
21. After unscrewing the crankshaft pulley mounting bolt, check that the mark on the pulley is aligned with the number 0 on the pointer.
22. Remove the drive belt pulley from the crankshaft.
23. Remove the lower timing belt cover with gasket.
24. Remove the timing belt from the crankshaft pulley.
25. If the belt is to be reinstalled, check that the marks on the timing belt and crankshaft pulley are aligned.
26. Remove the lower idler pulley.
27. Remove the crankshaft pulley.
Examination
Caution! Do not twist or bend the timing belt. Avoid getting oil, coolant or fuel on the timing belt.
Warning! If the timing belt breaks while the engine is running, the pistons may have hit the valves, causing the valves to be bent. Check the valve clearances. The valve clearances on bent valves will be significantly larger than required.
1. Remove the idler pulleys and check the condition of their bearings. Check the condition of the spring and check the length of the spring in a free state.
2. If the timing belt teeth have chipped, the distributor, water pump, oil pump or camshaft may be seized.
3. If there is significant wear or delamination on the outer surface of the timing belt, check the condition of the idler pulley raceway.
4. If there is wear or damage on only one side of the belt, check the timing belt guide and timing belt pulley alignment.
5. Check the timing belt tensioner mechanism for fluid leaks.
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6. By pressing the tensioner pusher, check the tightness of the tensioner and the absence of the pusher movement. If the pusher enters the tensioner, replace the tensioner.
7. Check the tappet protrusion from the tensioner housing. If the tappet protrusion is different from the required value, replace the tensioner.
Installation
1. Check that the mark on the crankshaft pulley is aligned with the protrusion on the oil pump housing (A) and install the pulley retainer and bolt (B).
2. Apply a product to the thread of the lower idler pulley mounting bolt to prevent the bolt from loosening, install the lower idler pulley and secure it with the bolt, tightening the bolt to the required torque.
3. Install the timing belt on the crankshaft pulley and the lower idler pulley, aligning the marks on the timing belt and the crankshaft pulley.
4. Install the timing belt guide to the crankshaft pulley.
5. Install the lower timing belt cover with gasket.
6. Install the drive belt pulley onto the crankshaft and secure it with the bolt, while holding the crankshaft from turning.
7. Install the upper idler pulley and secure it with the bolt, tightening it to the required torque.
8. Install the timing belt pulley onto the left camshaft, making sure the camshaft locating pin fits into the pulley recess. Hold the camshaft from turning with a wrench and tighten the camshaft pulley mounting bolt.
9. Recheck the alignment of the timing marks.
10. Check that the right camshaft dowel pin is at the top. If not, remove the cylinder head cover and use a wrench to turn the camshaft until the mark on the camshaft pulley aligns with the pointer on the rear timing belt cover.
11. Turn the left camshaft pulley clockwise one tooth. Install the timing belt on the pulley and turn the pulley to its original position.
12. Install the pulley onto the right camshaft. The camshaft's locating pin must fit into the pulley's recess.
13. Secure the pulley with a bolt, while using a wrench to hold the camshaft from turning.
14. Install the timing belt onto the camshaft pulley. If the timing belt is reused, align the marks made earlier.
15. Using a press or vice, slowly press the timing belt tensioner pusher into the housing and secure it in position with a steel rod inserted through the hole in the tensioner and pusher housing.
16. Install the upper timing belt cover.
17. Further installation is carried out in the reverse order of removal.