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Timing Belt, Replace

J462400

Remove

1. Disconnect battery negative lead

2. Raise vehicle

3. Remove engine and transmission undershield from vehicle

4. Remove right splash shield

• Remove 2x bolt, screw

• Release wash pipe (if installed) from 2x support clip

5. Remove blanking bolt (1) from cylinder block Note: To allow installation of Positioning Pin KM-6031.

6. Install Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”

Page 1 of 21110395Timing Belt, Replace

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7. Remove ribbed V-belt from engine

• Rotate tension roller clockwise, then lock using Locating Pin KM-6130 Note: Illustration shows vehicle with air conditioning. For vehicles without air conditioning the tension roller is rotated anti-clockwise.

8. Remove tension roller for ribbed V-belt from engine

• Remove bolt (1)

9. For vehicles with air conditioning, remove guide roller (1) for ribbed V-belt from support bracket

• Remove bolt



10. Lower vehicle

11. Remove cylinder head trim cover

• Remove 3x bolt

• Release 3x clip

12. Release harness and fuel line (1) from bracket for engine damping block, then move to one side

• Release 2x clip

13. Release power steering reservoir from front panel

• Release clip



14. Remove bracket with engine damping block, right side, and upper engine stabiliser

• Remove 12 mm bolt from engine stabiliser

• Remove 3x 10 mm bolt from bracket

• Remove 3x 10 mm bolt from engine damping block

15. Release timing belt cover from engine

• Remove 2x bolt (1)



16. Raise vehicle

17. Install Positioning Pin KM-6031 (1) to crankshaft Note: To determine top dead centre (TDC).

• Rotate crankshaft clockwise until positioning locates fully into crankshaft recess

18. Lower vehicle

19. Check mark (1) on camshaft pulley is visible through hole in timing belt cover Note: If incorrectly aligned, remove Positioning Pin KM-6031, rotate the crankshaft 360° clockwise, and reinstall the positioning pin.



20. Raise vehicle

21. Remove timing belt cover from engine

• Remove 2x bolt (1)



22. Lower vehicle

23. Apply match mark (1) on rear cover, in-line with mark (2) on camshaft pulley

24. Raise vehicle

25. Install Flywheel Locking Tool KM-911



26. Remove Positioning Pin KM-6031 from crankshaft

27. Remove crankshaft pulley from engine

• Remove bolt (1)

28. Remove Flywheel Locking Tool KM-911

29. Install Positioning Pin KM-6031 to crankshaft

30. Remove timing belt from engine

• Release nut (1) from tensioner



Install

31. Lower vehicle

Important: Ensure the timing belt is installed with the direction arrows pointing clockwise.

32. Install new timing belt to camshaft pulley and fuel pump pulley

• Align mark (2) on timing belt with match mark (1) on rear cover and mark (3) on camshaft pulley

33. Raise vehicle

34. Install timing belt to tensioner, crankshaft timing belt pulley and coolant pump

• Align mark (1) on timing belt with mark (2) on crankshaft timing belt pulley



35. Carry out final check of installation of timing belt around pulleys and tensioner

36. Install spacer (1) of Tensioning Tool KM-6234 to crankshaft toothed pulley

• Install spacer with crankshaft bolt Note: Do not over tighten bolt.



Adjust

37. Install bolt (1) to tensioner

• Tighten bolt until tensioner pulley touches timing belt


39. Tension timing belt

• Install Timing Belt Tensioner KM-6234 to crankshaft spacer

• Turn bolt of KM-6234 with torque wrench 11 Nm

• Remove Timing Belt Tensioner KM-



6234 from crankshaft spacer

40. Adjust tension of timing belt

• Place pick up of Tester KM-6225 next to timing belt

• Turn bolt (1) until Tester KM-6225 indicates tension of 95 Hz ± 3 Hz

41. Pre-tighten tensioner nut (1) 10 Nm



42. Rotate crankshaft 720° clockwise

43. Install Positioning Pin KM-6031 to crankshaft Note: To determine top dead centre (TDC).

• Rotate crankshaft clockwise until positioning pin enters recess in crankshaft


45. Apply pre-tension to timing belt

• Install Tensioning Tool KM-6234 to crankshaft spacer

• Turn bolt of tensioning tool with torque wrench 11 Nm

• Remove tensioning tool from crankshaft spacer

46. Check tension of timing belt

• Place pick up of Tester KM-6225 next to timing belt and check whether timing belt now has tension of 90 Hz ± 3 Hz

• If not, correct adjustment and check



again

47. Secure tensioner nut (1) for timing belt 50 Nm

48. Remove bolt (1) from timing belt tensioner



Install

49. Remove spacer (1) of Tensioning Tool KM-6234 from the crankshaft timing belt pulley

50. Install timing belt cover to engine

• Install 2x bolt (1) 10 Nm



51. Install Flywheel Locking Tool KM-911

52. Install crankshaft pulley to engine

• Install new bolt 20 Nm + 115º ± 15º



53. Remove Flywheel Locking Tool KM-911

54. Lower vehicle

55. Install timing belt cover to engine

• Secure 2x bolt (1) 10 Nm

56. Install bracket with engine damping block, right side, and upper engine stabiliser

• Install 3x 10 mm bolt to engine damping block 44 Nm

• Install 3x 10 mm bolt to bracket 60 Nm in correct sequence Note: Ensure the washers move freely on the bolts.



• Install 12 mm bolt to engine stabiliser 100 Nm

57. Secure power steering reservoir to front panel

• Secure clip

58. Secure harness and fuel line (1) to bracket for engine damping block

• Secure 2x clip

59. Install cylinder head trim cover

• Secure 3x clip

• Install 3x bolt

60. Raise vehicle

61. Remove Engine Support KM-6210-A from vehicle

62. For vehicles with air conditioning, install new guide roller (1) for ribbed V-belt to support bracket



• Install bolt 21 Nm

63. Install new tension roller for ribbed V-belt to engine

• Install bolt (1)

64. Install new ribbed V-belt to engine

• Rotate tension roller clockwise, then remove Locating Pin KM-6130 Note: Illustration shows vehicle with air conditioning. For vehicles without air conditioning the tension roller is rotated anti-clockwise.



65. Install blanking bolt (1) to cylinder block 20 Nm

66. Install right splash shield

• Secure 2x bolt, screw 8 Nm

• Secure wash pipe (if installed) to 2x support clip

67. Install engine and transmission undershield to vehicle



68. Lower vehicle

69. Connect battery negative lead

70. Program all volatile memories



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Documents

tension timing belt

new timing belt

release timing belt

timing belt cover note

timing belt tensioner

crankshaft pulley

crankshaft bolt note

bolt file