Toyota Celica 1994-1998 Repair Guide

Timing Belt and Sprockets

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REMOVAL & INSTALLATION



5S-FE Engine

See Figures 1 through 13



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Fig. Fig. 1: Exploded view of the timing belt and related components-5S-FE engine

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Remove the alternator and alternator bracket.
  4.  
  5. Raise and support the vehicle safely. Remove the right tire and wheel assembly.
  6.  
  7. Remove the right side engine undercover.
  8.  
  9. Remove the power steering belt.
  10.  
  11. Disconnect the ground strap connector.
  12.  
  13. Raise the engine enough to move the right side engine mounting assembly.
  14.  
  15. Remove the spark plugs.
  16.  
  17. Remove the No. 2 timing cover.
  18.  
  19. Position the number one cylinder to TDC on the compression stroke by turning the crankshaft pulley and aligning its groove with the timing mark 0 of the No. 1 timing belt cover. Check that the hole of the camshaft timing pulley is aligned with the alignment mark of the bearing cap. If not, turn the crankshaft one revolution 360°.
  20.  
  21. Remove the timing belt from the camshaft timing pulley.
    1. If reusing the belt, place matchmarks on the timing belt and the camshaft pulley. Place matchmarks on the timing belt to match portion A of the No. 1 timing belt cover. Loosen the mount bolt of the No. 1 idler pulley and position the pulley toward the left as far as it will go. Tighten the bolt. Remove the belt from the camshaft pulley.

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      Fig. Fig. 2: Matchmark locations for timing belt removal-5S-FE engine



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      Fig. Fig. 3: Loosen the bolt of the No. 1 idler pulley, then shift the it to the left as far as it will go

    2.  

  22.  
  23. Remove the camshaft timing pulley. Use a suitable pulley retaining tool and ratchet and remove the bolt and the camshaft pulley.
  24.  
  25. Remove the crankshaft pulley. Use a suitable crankshaft pulley retaining tool to hold the crankshaft pulley and remove the pulley set bolt and pulley using a puller.
  26.  
  27. If reusing the timing belt, after loosening the pulley bolt, check that the timing belt matchmarks align with the portion A of the No. 1 timing belt cover when the crankshaft pulley groove is aligned with the timing mark 0 of the No. 1 cover. If the marks does not align, use the following to do so:
  28.  



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Fig. Fig. 4: Checking the alignment of the marks with portion A and No. 1 belt cover

  1. When the matchmark is misalinged clockwise, pull the belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise. After aligning the matchmark, hold the timing belt and turn the crankshaft pulley clockwise. Align its groove with the timing mark 0 of the No. 1 belt cover.
  2.  
  3. If the matchmark is misaligned counterclockwise, align the mark by pulling the timing belt up on the no. 1 idler pulley side while turning the crankshaft pulley clockwise. After the alignment, hold the timing belt. And turn the crankshaft pulley counterclockwise m and align its groove with the timing mark 0 of the No. 1 cover.
  4.  
  5. Remove the timing pulley bolt. Next remove the crankshaft pulley.

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    Fig. Fig. 5: Misaligned clockwise, pull the belt up and turn the crankshaft pulley counterclockwise ...



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    Fig. Fig. 6: ... hold the timing, turn the pulley clockwise to align the groove with the timing mark



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    Fig. Fig. 7: Misaligned counterclockwise, pull the belt up on the No. 1 idler pulley, while turning the crankshaft pulley clockwise ...



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    Fig. Fig. 8: ... hold the timing belt, turn the crankshaft pulley counterclockwise and align its groove

  6.  

  1. Unbolt and remove the No. 1 timing belt cover.
  2.  

  1. Remove the timing belt and the belt guide. If reusing the belt mark the belt and the crankshaft pulley in the direction of engine rotation and matchmark for correct installation.
  2.  



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Fig. Fig. 9: Place a rotation mark on the timing belt prior to removal if reusing the old belt

  1. Remove the No. 1 idler pulley and the tension spring.
  2.  
  3. Remove the No. 2 idler pulley.
  4.  
  5. Remove the crankshaft timing pulley. If the pulley cannot be removed by hand, use two prying tools with shop rags behind them to prevent damage to the engine.
  6.  



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Fig. Fig. 10: Remove the crankshaft timing pulley ...

  1. Remove the oil pump pulley.
  2.  



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Fig. Fig. 11: ... and the oil pump pulley

  1. Inspect the belt for defects and replace as required. Inspect the idler pulleys and springs; replace the defective components as required.
  2.  

To install:
  1. Align the cutouts of the oil pump pulley and shaft. Install the oil pump pulley and tighten the retaining nut to 18 ft. lbs. (24 Nm).
  2.  
  3. Install the crankshaft timing pulley.
  4.  



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Fig. Fig. 12: Slide the timing pulley facing the angle sensor inward

  1. Align the timing pulley set key with the key groove of the pulley.
  2.  
  3. Slide on the timing pulley with the flange side facing inward.
  4.  

  1. Install the No. 2 idler pulley and tighten the bolt to 31 ft. lbs. (42 Nm). Be sure that the pulley moves freely. Use the 1.38 inch (35mm) bolt only.
  2.  

  1. Temporarily install the No. 1 idler pulley and tension spring. Pry the pulley toward the left as far as it will go. Tighten the bolt. Make sure that the pulley rotates freely. Only use the 1.65 inch (42mm) bolt.
  2.  
  3. Temporarily install the timing belt.
    1. Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body.
    2.  
    3. If reusing the old belt, align the marks made during removal, and install the belt with the arrow pointing in the direction of the engine revolution.

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      Fig. Fig. 13: Align the points marked on the gears and belt during removal!

    4.  

  4.  
  5. Install the timing belt guide with the cup side facing outward.
  6.  
  7. Install the No. 1 timing belt cover.
  8.  
  9. Install the crankshaft pulley. Align the pulley set key with the key groove of the pulley and slide on the pulley. Tighten the bolt to 80 ft. lbs. (108 Nm).
  10.  
  11. Install the camshaft timing pulley.
    1. Align the camshaft knock pin with the knock pin groove of the pulley and slide on the timing pulley. Tighten the bolt to 40 ft. lbs. (54 Nm).
    2.  

  12.  
  13. With the No. 1 cylinder set at TDC on the compression stroke install the timing belt (all timing marks aligned). If reusing the belt, align with the marks made during the removal procedure.
    1. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the No. 1 timing belt cover. Make sure the camshaft sprocket hole is aligned with the mark on the bearing cap.
    2.  

  14.  
  15. Connect the timing belt to the camshaft timing pulley.
  16.  
  17. Check that the matchmark on the timing belt matches the end of the No. 1 timing belt cover.
  18.  
  19. Once the belt is installed be sure that there is tension between the crankshaft timing pulley and the camshaft pulley.
  20.  
  21. Check the valve timing.
    1. Loosen the No. 1 idler pulley mount bolt 1 / 2 turn. Turn the crankshaft pulley two revolutions from TDC in the clockwise direction. Always turn the crankshaft pulley clockwise.
    2.  
    3. Make sure that the all the timing marks are aligned.
    4.  
    5. Slowly turn the crankshaft pulley 1 7 / 8 revolutions. Align its groove with the mark at 45°BTDC on the No. 1 timing belt cover for the No. 1 cylinder.
    6.  
    7. Tighten the No. 1 idler pulley mount bolt to 31 ft. lbs. (42 Nm).
    8.  

  22.  
  23. Install the No. 2 timing belt cover.
    1. Install the upper gasket to the No. 1 timing belt cover.
    2.  
    3. Disconnect the engine wire protector between the cylinder head cover and the No. 3 timing belt cover.
    4.  
    5. Install the gasket to the timing belt cover.
    6.  
    7. Install the belt cover.
    8.  
    9. Install the engine wire protector to the two mounting bolts of the No. 2 timing belt cover. Install the right side first.
    10.  
    11. Install the engine wire protector to the alternator bracket and adjusting bar.
    12.  

  24.  
  25. Install the spark plugs and wires.
  26.  
  27. Tighten the right engine mount bracket bolts to 38 ft. lbs. (52 Nm).
  28.  
  29. Lower the engine after installing the bracket.
  30.  
  31. Tighten the engine mount insulator bolt to 47 ft. lbs. (64 Nm). Tighten the through-bolt to 54 ft. lbs. (78 Nm).
  32.  
  33. Install the power steering reservoir bracket, tighten the bolt to 21 ft. lbs. (28 Nm).
  34.  
  35. Install the power steering reservoir to the bracket. Tighten the bolt to 27 ft. lbs. (37 Nm) and the nut to 38 ft. lbs. (52 Nm).
  36.  
  37. Connect the ground strap wiring.
  38.  
  39. Install the power steering pump drive belt.
  40.  
  41. Install the front wheel.
  42.  
  43. Install the alternator.
  44.  
  45. Install the engine undercover.
  46.  
  47. Lower the vehicle and connect the negative battery cable.
  48.  
  49. Check all fluid levels and adjust all drive belts. Perform all necessary engine adjustments. Road test the vehicle for proper operation.
  50.  

7A-FE Engine

See Figures 14 through 31

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  



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Fig. Fig. 14: View of the timing belt, gears and cover along with other related components-7A-FE engine


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.

  1. Loosen the lugnuts on the right front wheel.
  2.  
  3. If equipped with cruise control, remove the cruise control actuator cover, cruise control electrical connector, control cable and the actuator from the vehicle.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the right front wheel and housing cover.
  8.  
  9. Slightly jack up the engine and remove the right-hand engine mounting insulator.
  10.  



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Fig. Fig. 15: Jack up the engine enough to remove the weight from the RH mounting

  1. Loosen the water pump pulley bolts.
  2.  
  3. Unbolt and remove the alternator.
  4.  
  5. If equipped with A/C, remove the compressor and bracket.
  6.  
  7. Loosen the power steering pump pivot and lock bolts.
  8.  
  9. Push the power steering pump toward the engine and remove the drive belt.
  10.  
  11. Remove the water pump pulley.
  12.  
  13. Unbolt and separate the wire harness protector from the cylinder head.
  14.  
  15. Remove the spark plug wires and the spark plugs from the cylinder head.
  16.  
  17. Remove the two hose clamps, label and extract the PCV hoses from the valve cover.
  18.  
  19. Remove the four cap nuts, the seal washers, the valve cover, and the gasket from the cylinder head.
  20.  
  21. Turn the crankshaft to align the timing mark on crankshaft pulley at 0 , setting the piston in No. 1 cylinder at Top Dead Center (TDC) on the compression stroke. Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, turn crankshaft pulley 1 complete revolution (360 degrees).
  22.  



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Fig. Fig. 16: Verify that the timing mark on the crankshaft pulley is TDC



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Fig. Fig. 17: Alignment of the hole on the camshaft timing pulley

  1. If necessary, remove the four bolts and retaining the pulley from water pump.
  2.  
  3. While retaining the crankshaft pulley, remove the pulley bolt. Extract the crankshaft pulley using a puller.
  4.  
  5. Unbolt all three timing belt covers from the engine.
  6.  
  7. Slide the timing belt guide from crankshaft.
  8.  



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Fig. Fig. 18: Slide the timing belt guide off the crankshaft

  1. Set the camshaft and crankshaft timing sprockets to align the marks.
  2.  

Do not turn crankshaft or camshaft independently after removal of timing belt. Binding or damage to engine components could result. If timing belt is to be reused, mark timing belt with arrow showing direction of engine revolution. Put matchmarks where timing belt meets with crankshaft timing sprocket and camshaft timing sprocket to ensure installation in the same position.



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Fig. Fig. 19: Draw an arrow in the direction of the belt if you are reusing the timing belt



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Fig. Fig. 20: Also mark the points of the belt vs. the gear so the teeth match during installation



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Fig. Fig. 21: Marked crankshaft timing sprocket

  1. Remove the timing belt tensioner bolt, tensioner, and the tension spring.
  2.  



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Fig. Fig. 22: Remove the crankshaft timing pulley by prying it off if necessary


WARNING
Do not bend, twist or turn the timing belt inside out. Do not allow the belt to come in contact with oil, coolant or steam.

  1. Loosen the mounting bolt of the idler pulley and shift the pulley toward the left as far as it will go, them temporarily tighten it.
    1. Remove the timing belt from camshaft and crankshaft timing sprockets.

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      Fig. Fig. 23: Loosening the idler pulley mounting bolt while moving it to the far left, then ...



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      Fig. Fig. 24: ... lift the belt off the gear assemblies



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      Fig. Fig. 25: Then remove the idler pulley

    2.  

  2.  
  3. Remove the camshaft timing sprocket bolt while holding the camshaft by the hexagonal wrench head section.
  4.  


WARNING
Be careful not to damage the cylinder head when holding camshaft in place.



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Fig. Fig. 26: Hold a hexagonal head wrench portion of the camshaft, then remove the bolt and camshaft timing pulley



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Fig. Fig. 27: The timing pulley should slide off the end of the camshaft

  1. Remove crankshaft timing sprocket using 2 flat bladed prybars to pry off. Tape the end of the prybars to prevent damaging the crankshaft.
  2.  



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Fig. Fig. 28: Slide the crankshaft timing pulley off by hand if possible

To install:
  1. Check the camshaft and crankshaft timing sprockets to align the marks. Do not turn crankshaft or camshaft independently before installation of the timing belt or engine damage may occur.
  2.  
  3. Install the camshaft timing sprocket. Align the camshaft key with the groove on the sprocket and slide the sprocket on the camshaft; secure with the camshaft timing sprocket bolt. Hold the camshaft at hexagonal wrench head portion to prevent rotation and tighten the camshaft timing sprocket bolt to 43 ft. lbs. (59 Nm).
  4.  

Inspect the camshaft timing sprocket to ensure mark is still aligned as indicated.

  1. Install the crankshaft timing sprocket. Align the pulley set key with the groove of the pulley. Slide the timing pulley on the crankshaft, facing the flange side inward.
  2.  

Inspect the crankshaft timing sprocket to ensure mark is still aligned as indicated.

  1. Temporarily install the idler pulley and tension spring. Install the idler pulley with the bolt. Do not tighten the bolt yet. Install the tension spring. Push the pulley toward the left as far as it will go and tighten the bolt.
  2.  
  3. Set the No. 1 cylinder to TDC.
    1. 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.  
    3. Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft pulley and oil pump body.
    4.  

  4.  
  5. Install the timing belt. If reinstalling the old belt, observe the matchmarks made during removal. Make sure the belt is fully and squarely seated on the sprockets.
  6.  
  7. Check the valve timing as follows:
    1. Loosen the retaining bolt for the timing belt tensioner and allow it to tension the belt.
    2.  
    3. Temporarily install the crankshaft pulley bolt and turn the crank clockwise 2 full revolutions from TDC to TDC. Insure that each timing mark realigns exactly.
    4.  
    5. Tighten the timing belt tensioner bolt to 27 ft. lbs. (37 Nm).

      Click image to see an enlarged view

      Fig. Fig. 29: On valve timing, make sure each pulley aligns with the timing marks, if not remove the belt and reinstall

    6.  

  8.  
  9. Measure the timing belt deflection at the SIDE point, looking for 0.20-0.24 inch (5-6mm) of deflection at 4.4 pounds of pressure. If the deflection is not correct, adjust with the timing belt tensioner.
  10.  
  11. Install the timing belt guide, remove the temporarily installed crankshaft pulley bolt. Install the guide with the cup side facing outward, onto the crankshaft and install the timing belt covers from the lowest to the highest. Tighten the nine cover bolts to 62 inch lbs. (7 Nm).
  12.  



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Fig. Fig. 30: Install the timing belt guide with the cup side facing outwards

  1. Install the crankshaft pulley to the crankshaft after aligning the pulley key with the slot on the pulley; secure with the bolt while holding the crankshaft pulley and tighten the pulley bolt to 87 ft. lbs. (118 Nm).
  2.  

  1. Install the new valve cover gasket and seal washers to the cylinder head cover.
  2.  
  3. Install the cylinder head cover to the cylinder head; secure with four cap nuts to 53 inch lbs. (6 Nm).
  4.  
  5. Install two PCV hoses to the valve cover; secure with hose clamps.
  6.  
  7. Install the spark plugs and spark plug wires.
  8.  
  9. Attach the engine wiring harness to the valve cover, then install the engine wiring harness cover and secure to 53 inch lbs. (6 Nm).
  10.  
  11. Install the water pump pulley but do not tighten the bolts at this time.
  12.  
  13. Install the PS pulley and pull the pump back to tighten the drive belt. Tighten the pivot and adjusting bolt to 29 ft. lbs. (39 Nm).
  14.  

  1. If equipped, install the A/C pipe mounting bracket and tighten the bolts to 35 ft. lbs. (47 Nm).
  2.  
  3. Install the A/C compressor and tighten the bolts to 18 ft. lbs. (25 Nm), then attach the compressor connector.
  4.  
  5. Install and secure the alternator.
  6.  
  7. Install the drive belt with the adjusting bolt and install the idler pulley locknut and tighten the nut and adjusting bolt to 29 ft. lbs. (39 Nm).
  8.  
  9. Install the alternator drive belt and tighten the pivot bolt to 45 ft. lbs. (61 Nm), then the adjusting lock bolt to 14 ft. lbs. (19 Nm).
  10.  
  11. Tighten the water pump pulley bolts to 82 inch. lbs. (9 Nm).
  12.  
  13. Install engine mount to body and secure but do not tighten fully. Tighten the following:

    Mounting bracket-to-engine mount bolt to 47 ft. lbs. (64 Nm).
     
    Mounting bracket-to-engine mount nuts to 38 ft. lbs. (52 Nm).
     
    Engine mount-to-body bolt A to 19 ft. lbs. (25 Nm).
     
    Engine mount-to-body bolts B to 19 ft. lbs. (25 Nm).
     
    Engine mount-to-body bolt C to 19 ft. lbs. (25 Nm), if equipped with cruise control.
     

  14.  



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Fig. Fig. 31: RH engine mounting nut and bolt locations-7A-FE engine

  1. Install the right engine undercover.
  2.  
  3. Install the right front wheel and lower the vehicle.
  4.  
  5. If equipped with cruise control, install the actuator.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check the ignition timing. Inspect for leaks and check vehicle operation.
  10.  

INSPECTION



Idler Pulley

See Figures 32 and 33

Visually inspect the seal portion of the idler pulley for oil leakage. Check that the idler pulley turns smoothly in each direction. If necessary, replace the pulley.



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Fig. Fig. 32: Check the rotation of the bearing, is it a smooth turn-



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Fig. Fig. 33: Inspect the seal of the bearing for any oil seepage

Tension Spring

See Figure 34

  1. Measure the free length of the tension spring. Free length should be:

    7A-FE engine-1.252 inch (31.8mm)
     
    5S-FE engine-1.811 inch (46.0mm)
     

  2.  
  3. If the free length is not within specifications, replace the tension spring.
  4.  
  5. Measrue the tension of the spring at the specified length. Installed tension should be as follows:

    7A-FE engine-10.8-11.7 lbf (48-52 N) @ 1.480 inch (37.6mm)
     
    5S-FE engine-7.2-8.3 lbf (32-37 N) @ 1.988 inch 950.5mm)
     

  6.  
  7. If the tension is not within specifications, replace the spring.
  8.  



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Fig. Fig. 34: Measure the free length of the tension spring

Belt

See Figures 35, 36, 37, 38 and 39



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Fig. Fig. 35: Check for premature parting of the belt



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Fig. Fig. 36: Check if the teeth are cracked or damaged



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Fig. Fig. 37: Look for noticeable cracks or wear on the belt face


WARNING
Do not bend or twist the timing belt inside out. Do not allow the timing belt to come in contact with any oil, water or steam.

  1. If there are any defects in the timing belt as shown in the illustrations, replace the belt. If premature parting is a concern, check for proper belt installation or the timing cover gasket for damage and improper installation.
  2.  
  3. If the belt teeth are cracked or damaged, check to see if either camshaft or the water pump is locked.
  4.  
  5. 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.
  6.  
  7. If there is noticeable wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
  8.  
  9. If there is noticeable wear on the teeth, check the timing cover for damage and check that gasket for correct installation. Also inspect for foreign materials on the pulley teeth.
  10.  



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Fig. Fig. 38: You may only have damage on one side of the belt; if so, the guide could be the culprit



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Fig. Fig. 39: Foreign materials can get in between the teeth and cause damage

 
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