Timing Belt Replacement (4A-FE Engine) - Inspection

· Inspect the timing belt for wear and cracks.

· Inspect the tensioner pulley if cracks are found on the outer surface of the belt.

· If one-sided belt wear is found, inspect the belt guide roller and pulley alignment.

· Check that the tensioner pulley rotates smoothly and has no play. Replace if necessary.

· Check the free length of the tensioner spring; it should be 35.3 mm (Fig. 2.3.1.2). Check the spring tension at a length of 43.6 mm. It should be 35-39 N (3.6-4.0 kg). Replace the spring if necessary.

Fig. 2.3.1.2. Checking Free Length of Timing Belt Tensioner Spring

Installation (4A-FE Engine) · Align the dowel pin on the camshaft with the groove on the camshaft timing pulley and slide the timing pulley onto the shaft.

· Tighten the timing pulley bolt while holding the camshaft with a wrench on the hexagonal section.

· Install the woodruff key in the crankshaft aligned with the keyway of the timing pulley, and slide the pulley onto the shaft with the raised edge facing inward. · Install the tensioner pulley with its mounting bolt, but do not tighten it yet. · Install the spring, push the tensioner pulley as far to the left as possible, and tighten the bolt.

· Align the hole in the camshaft timing pulley with the mark on the bearing cap by turning the camshaft with a wrench on the hexagonal section.

· Align the marks on the crankshaft timing pulley and the oil pump housing by turning the crankshaft.

· Install the timing belt (when reusing the belt, observe the marks made during removal) and check the belt tension between the camshaft and crankshaft timing pulleys.

· Loosen the tensioner pulley bolt and slowly turn the crankshaft two full revolutions clockwise.

· Check that the marks on both timing pulleys are aligned. (If not, remove the timing belt and install it again.)

· Tighten the tensioner pulley bolt.

· Remove the crankshaft pulley bolt.

· Check the timing belt deflection between the camshaft and crankshaft timing pulleys. It should be 5-6 mm at 20 N (2 kg). If not, adjust the tensioner pulley again.

· Install the timing belt guide roller with the hollow edge facing outward.

· Install the timing belt covers (from bottom to top).

· Install the pulley onto the crankshaft nose and tighten the pulley bolt.

· Install the cylinder head cover with a new gasket.

· Connect the crankcase ventilation hoses and the spark plug wires.

· Install the wiring protector, wires and spark plug boots.

· Install the water pump pulley and the alternator drive belt.

· Adjust the belt tension. Deflection between the water pump and alternator at 98 N (10 kg) should be 7-9 mm for a new belt, and 11.5-13.5 mm for a used belt.

· After installing a new alternator belt, run the engine for 5 minutes and recheck the belt tension.

· Install the splash shield and right front wheel, then lower the vehicle to the ground.

· Install and fill the windshield washer reservoir, then connect the negative battery cable.