Timing Belt: Service and Repair

TOOTHED BELT, REMOVING AND INSTALLING

Removing




- Remove engine cover.




- Remove noise insulation panel (arrows).
- Lock carrier in service position, refer to Body and Frame/Radiator Support/Service and Repair/Lock Carrier/Moving Into Service Position [1][2]Procedures
- Ribbed belt, removing and installing, refer to Drive Belts/Mounts, Brackets and Accessories/Drive Belts/Serpentine Belt/Service and Repair Service and Repair
- Unclip toothed belt guard on both sides and remove.




- Turn crankshaft at central bolt of toothed belt gear in direction of engine rotation to cyl. 3 TDC. Timing marks -A- and -B- must be aligned.




- Check position of camshafts. Large holes (arrow) of securing plates on camshaft sprockets must face toward inside and align.
If not, turn crankshaft one revolution further.
- Remove sealing plug from left-side of cylinder block.
- Top Dead Center (TDC) mark on crankshaft must be visible or be felt behind bore of removed sealing plug.

WARNING: DO NOT turn crankshaft while checking for TDC mark. Personal injury may result.




- Install 3242 crankshaft holder into sealing plug opening.
- Remove tensioner for ribbed belt.
- Remove center and right toothed belt guards.

CAUTION: Before removing ribbed belt, note direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a used belt can destroy the belt. When installing the ribbed belt, make sure it is seated correctly on the pulley.

Notes: The toothed belt tensioner is oil dampened. Compress it by slowly applying constant pressure.
Use spring clamp from 2024A.




- Using 8 mm hex wrench, turn toothed belt tensioning roller -1- clockwise until tensioning lever -2- compresses tensioner -3- so that spring clamp (2 mm diameter) can be inserted into bore and lifter.
- Insert pin and release tension.
- Remove vibration damper, refer to Cylinder Block Assembly/Harmonic Balancer/Service and Repair Service and Repair




- Remove idler wheel for ribbed belt (arrows).
- Remove toothed belt.

Installing




- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approximately 5 turns.
- Remove 3391 camshaft locator bar.




- Remove both camshaft sprockets using T40001 special tool.
- Reinstall both camshaft sprockets together with locking plates and hand-tighten.

Note: The camshaft sprockets should be loose enough on the cone to be turned, but not so loose as to be tipped.




- Install toothed belt on all sprockets as shown in illustration.
- Install 3391 camshaft locator bar.




- Using 8 mm hex wrench, turn toothed belt tensioner roller -1- clockwise in direction shown (arrow) until spring clamp can be removed.
- Before starting engine for first time, pre-load tensioning roller as follows:
- Apply torque wrench to hex socket on tensioning roller.




- Pre-load tensioning roller to 15 Nm (11 ft lb) in direction of tension. This provides correct adjustment.