Friday, March 23, 12

Transcription

1

2 1kzt-e timing belt How-To

3 About this manual Disclaimer This manual is intended to serve as an overall guide to perform the procedure outlined within. Diesel Toys accepts no liability for content or procedures described. All services should be performed by an experienced technician. You may not modify, copy, publish, transmit, display, distribute, or sell any information from this document without the expressed written consent of Diesel Toys. Always wear safety goggles!

4 Tools required: 3/8 socket wrench 3/8 impact wrench 10mm socket 12mm socket 14mm socket 19mm socket 22mm socket rubber mallet needle-nosed pliers 3/8 breaker bar small pin or screwdriver drain pan vise Models covered: kzn130-kzn185

5 Getting Started If your water pump has not been replaced, now is a good time to do it. We cover water pump replacement in another tutorial. We started with the engine removed from the vehicle; in order to get us on the same page, follow the procedures below. 1.Place vehicle in park 2.Chock wheels 3.Disconnect battery 4.Remove upper radiator hose 5.Remove fan shroud (4x10mm) 6.Remove cooling fan (4x12mm) 7.Remove cooling fan pulley

6 Timing cover Using needle nosed pliers, remove the clips to the timing belt cover (x2).

7 Timing cover continued Remove all bolts attaching the timing cover (4x10mm).

8 Timing cover continued Remove plastic timing cover and place the bolts/clamps inside.

9 Setting TDC cam sprocket Injection pump pulley crank pulley Using a breaker bar, (22mm socket) rotate engine clockwise to TDC.

10 Setting TDC crank pulley cam sprocket Make sure that all of these marks line up. Start from the crank pulley, then check the cam sprocket, then the injection pump. On the injection pump the notch is on the rear side of the pulley injection pump

11 timing belt tensioner Remove the bolts attaching the timing belt tensioner (2x10mm).

12 timing belt tensioner Remove belt!

13 Timing belt cover I recommend replacing the cam seal at this time as it s easy to get to. This is a good time to clean up the plastic cover.

14 Cam seal replacement To keep the sprocket from moving, use the old belt as a belt wrench. An impact wrench is a must here! Careful to not change the TDC orientation of the cam sprocket while loosening the bolt WIth the alternator, a/c compressor, and timing belt removed, begin by removing the camshaft sprocket bolt and woodruff key (19mm).

15 Cam seal replacement Careful not to lose the woodruff pin during the process Remove pulley with a few light taps with a rubber mallet.

16 Cam seal replacement Remove the bolts attaching the timing cover (8x10mm). Using a rubber mallet and applying tension with a free hand, tap the rear of the intake side of the cover. Slide the cover off of the cam, then lift up and out avoiding the cam tensioner.

17 Cam seal replacement Using needle nosed pliers, gently remove the cam seal.

18 Cam seal replacement Pay special attention to the seam directly below the camshaft opening. Using a wire wheel (pictured) and an electric drill, clean all mating surfaces to remove old sealant, dirt, and oil.

19 Cam seal replacement Toyota part# With a cleaned cover, press the new seal in. It s best to try and use your fingers or other soft instruments as these seals are easily damaged.

20 Cam seal replacement the closest thing I can find to the factory sealant is Hondabond. Great stuff! Using Hondabond, run a bead along the seam and distribute evenly with your finger.

21 Cam seal replacement It may not be necessary, but most of these covers have sealant on the bottom of the cover from factory. I recommend repeating the practice. Now the cover is ready to install.

22 Cam seal replacement When installing the cover, begin with the bottom of the cover, then put it into position. Next, slide the cover over the camshaft then press and hold for 10 seconds. Install cover bolts and tighten to 9 ft/lbs in a crosshatch pattern.

23 Cam seal replacement Careful to not change the tdc orientation of the cam sprocket while tightening the bolt Place the woodruff key into the slot on the camshaft. Slide cam sprocket into position Install the bolt and torque to 72 ft/lbs using an impact wrench.

24 Cam seal replacement Cover and cam sprocket installed.

25 Tensioning the tensioner Careful! The tensioner can slip out of the vise and go flying! This procedure should take 3-4 minutes.you should not be able to tighten without stopping. if you can, the tensioner is bad Place the tensioner in a vise and slowly tighten the vise until the holes in the tensioner line up. Slide a small flat-blade screwdriver or other hardened metal pin through the holes in order to keep the holes lined up. Install tensioner but leave it loose for now. (2x10mm)

26 timing belt install Triple check the notches on crank, IP, and cam to ensure alignment during each step of this process Starting with the injection pump, slide the belt over the pulley then gauge the distance in order to have the yellow line on the cam sprocket line up with the mark on the gear. Adjust until perfect. Do not slide the belt over the tensioner until this orientation is right

27 timing belt install Slide belt over tensioner at this time. Check all your alignment marks one more time, then tighten the 2 bolts securing the tensioner to 9 ft/lbs. (2x10mm) Using needle nosed pliers remove pin on tensioner.

28 timing belt install IMPORTANT:if any of the marks are not right, start over! Tip: When rotating the engine-once you feel resistance, wait 5 seconds then continue Check your marks to ensure they have not moved. Using a breaker bar and turning clockwise, rotate the engine over 3 times watching all 3 timing marks during each rotation.

29 timing belt install Replace the plastic cover and install cover bolts and tighten to 9 ft/lbs (4x10mm). Install (2) metal clamps.

30 Finishing up 1.Reinstall cooling fan assembly 2.Reinstall fan shroud 3.Reinstall upper radiator hose 4.Reconnect battery 5.Remove radiator cap 6.Start engine 7.Top off any lost coolant 8.Un-chock wheels *If you found this how-to helpful, please send your opinions to