Toyota Starlet EP91 Cambelt

Timing belt replacement is overdue

Seems like there is no actual date nor any information att all depicting if this toyota has ever had a replacement of the timing belt done, ever.

This car is known and own by acquaintances since 2009, none of them has done a belt change.

Local toyota dealer had no record of it either.

As of writing this the car has done 15600km or 9600miles.
interval is supposed to be 6 years or 10000 - 12000km

car model year is 1997 so I guess it's time to do it.

There is a list of torque values at the bottom of the page

Generic belt path.

New timingbelt kit.
part no. is VKMA 91400 (SKF)
for engine code 4E-FE no AC

Teardown

Start with the wheelhouse cover.
attaches to some random fasteners

Loosen the locking nut for alternator.

And loosen the top one, aswell as
the one for the sliding bracket

This car has a servo, so it needs to be loosened .

This car has a servo, so it needs to be loosened
aswell.

Remove the belts and proceed to remove the
crankshaft harmonic balancer/pulley.
It is secured by four small bolts and one crankshaft bolt.
I did not need any special tools, it came loose without problem

Generic Toyota pulley

Belt cover

After belt and pulley removal covers can be removed

The cambelt is protected by two covers, secured by some
10mm bolts.
and a hidden one, behind grommet, see hole in picture below

Two separate covers.

Alignment

Before removal of belt, engine should be turned over to
TOD for cyl. 1 for the markings to align.

Crankshaft mark

Old timingbelt, removal

Old belt does not look too bad

The tensioner can be loosened and
a pry bar can be used to push it back from the belt.
lock it down to proceed.

Gently walk the belt of, try to avoid shifting axle
positions.

The idler, top right,
can be loosened and removed

Belt comparison

The markings does not match,
measurements looks ok.

Dual belt idlers, one is tensioner (left).

Replace the top pulley, be careful not to overtighten
approx 20-25nm.

Comparison, old vs new idler bearing.

Tensioner spring spec. is max 38.4 mm in length.
The oiginal one seemed ok, did not replace it.

Install the new tensioner, move it back as far as it can
and lock it down.

Add the new belt, set tension.

The belt, when in tension should be streched
on the side facing front of the car

When the belt is in place, loosen the locking bolt on the tensioner
The spring vill now stretch the belt a bit.
now doublecheck that markings have not moved, if ok proceed, otherwise correct timing belt teeth position.

if all looks ok, belt is taut and marking are correct, do the following:

Turn the crankshaft two full revolutions by hand, slowly, if anything locks up, do not reverse the engine!. solving that scenario might be difficult.

Check the timing marks again, top and bottom of engine, if ok, tighten the tensioner approx.18 Nm.

Turn the crankshaft two full revolutions by hand again
Check the timing marks again
twist the belt to check that it is taut. and nothing moves

If all is ok, reassembly can begin.

when reinstalling covers, do not forget the rubber seal between the top and bottom cover

Final

First start, it survived the procedure ; ).

-20210829

-20240112

Car is still operational, no issues.
It does not drive much, barely about 5000km since procedure.
- replacement @ 157010km
- currently @ 161380km

Torque values list 4E-FE

Tensioner: 18 Nm
Idler : 20/25 Nm
Main bearings Stage 1: 29 Nm
Main bearings Stage 2: 58 Nm
Big end bearings Stage 1: 20 Nm
Big end bearings Stage 2: 40 Nm
Oil pump : 7 Nm
Sump bolts : 8 Nm
Sump drain bolt : 25 Nm
Flywheel/driveplate : 90 Nm/88 Nm
Clutch pressure plate : 19 Nm
Crankshaft pulley/damper centre bolt : 155 Nm
Camshaft sprocket/gear : 51 Nm
Camshaft carrier/cap : 13 Nm
Camshaft/rocker cover : 7 Nm
Inlet manifold to cylinder head : 19 Nm
Exhaust manifold to cylinder head : 48 Nm
Spark plugs : 18 Nm
Lambda sensor (Oxygen) : 44 Nm
Front hub : 216 Nm
Steering track rod end : 47 Nm
Brake caliper to carrier Front:
-Removable carrier = 25 Nm
-Integral carrier = 18 Nm
Brake caliper/carrier to hub Front : 88 Nm
ABS sensor Front : 8 Nm
ABS sensor Rear : 8 Nm
wheels lugs: 103 Nm

Tensioner spring length : max 38.4 mm
Valve Clearance (Inlet) : 0.15-0.25mm
cold Valve Clearance (Exhaust) : 0.31-0.41mm
cold Compression Pressure : 9.8-12.7 bar
Oil Pressure : 2.6-3.6 bar @ 3000rpm
Rad Cap : 0.75-1 bar
Thermostat opens :80-84°C